Augmented Heat Up of Steam Turbines Using Saturated Steam
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Solution Overview
Problem
Large operational units such as steam turbines and reactors face rapid heating issues during startup after maintenance, leading to potential damage from uncontrolled steam condensation and part misalignment, resulting in extended downtime and production losses.
Innovation Solution
Incorporating saturated steam into a compressed gas flow, such as nitrogen, to increase the specific heat capacity of the heating medium, allowing for controlled and accelerated heating without condensation risks, using a system that monitors and controls the dew point and steam injection rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If full flow of steam is introduced to heat up the turbine, then heating speed is improved, but equipment damage risk increases due to uncontrolled condensation and aggressive heating
Solution Approach 1:
The patent introduces a mediator substance (inhibitor) that prevents condensation of steam on turbine surfaces. This intermediary chemical agent allows rapid steam heating while protecting the equipment from condensation-related damage, resolving the contradiction between heating speed and equipment safety
Solution Approach 2:
The patent changes the chemical parameters of the heating medium by adding inhibitor substances to the steam. This modifies the steam's properties to prevent condensation while maintaining its high heating capability, enabling fast heating without the harmful condensation effects
2Reliability
If slow controlled heating is used to prevent condensation damage, then equipment safety is improved, but startup time increases resulting in production losses
Solution Approach 1:
By introducing the inhibitor as a mediator, the system achieves both safety and speed: the inhibitor protects against condensation damage while allowing rapid heating, eliminating the need to choose between slow safe heating or fast dangerous heating
3Ease of repair
If new parts are installed in cold turbine, then repair work is completed, but vibration problems occur due to improper seating and misalignment
Solution Approach 1:
The patent applies preliminary thermal action by introducing heated steam with inhibitor before the turbine is fully operational. This preliminary heating expands the metal components and new parts, allowing them to seat properly in their intended positions before full operation, preventing vibration and misalignment issues
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables faster, controlled heating of units to operational temperatures, reducing downtime and vibration issues, potentially saving 25-40% of startup time and minimizing equipment damage.
Implementation Method 1
Incorporating saturated steam into a compressed gas flow, such as nitrogen, to increase the specific heat capacity of the heating medium
Implementation Method 2
at temperatures below 100° C. the steam can condense. The condensate can then be absorbed by the significant amounts of refractory
Implementation Method 3
a precise determination of the steam injection rate, or direct measure of the resulting dew point of the injection gas
Data Source
AI summary
A system and a method of augmenting the heat up of a unit using a compressed, heated gas that contains moisture such as steam or vaporized water such that the specific heat of the gas is increased. In a preferred embodiment, steam in compressed inert gas such as nitrogen is capable of augmenting the heat up cycle for units such as process reactor vessels, furnaces, process steam and power production boilers, turbines, and other production vessels.