HRSG Floor Pressure Control for Faster Startup
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Solution Overview
Problem
Combined cycle power plants face challenges in quickly establishing the required floor pressure levels in heat recovery steam generators (HRSGs) during startup, leading to prolonged start-up times and increased costs with existing methods.
Innovation Solution
A pressure controlling computing device is used to adjust the floor pressure levels by identifying candidate pressure levels, determining steam velocity limits, and selecting the lowest pressure level that does not exceed the velocity limit, allowing for earlier steam flow and pipe warming, thereby reducing start-up time without the need for expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If the HRSG is sealed to build pressure to floor pressure levels, then pressure is established for steam turbine admission, but steam flow is delayed and pipe warming time is extended
Solution Approach 1:
The patent applies partial action by pressurizing the HRSG to a sub-floor pressure level (lower than the required floor pressure) during the initial startup phase. This partial pressurization allows steam bypass valves to open earlier and establish steam flow through the piping system. The remaining pressure deficit is made up later by the gas turbine exhaust, achieving the required floor pressure without the time penalty of sealing to full floor pressure from the start.
Solution Approach 2:
The patent implements preliminary action by establishing steam flow through the bypass valves before the HRSG reaches full floor pressure. This preliminary steam flow initiates pipe warming earlier in the startup sequence, preventing the delay that would occur if the system waited until floor pressure was fully established before allowing any steam flow.
2Speed
If mechanical means or specialized equipment are used to reduce start times, then startup speed is improved, but capital investment and equipment costs increase
Solution Approach 1:
The patent applies self-service by using the gas turbine exhaust itself to make up the pressure difference after sub-floor pressurization. Instead of requiring external pressurization equipment or mechanical means, the system utilizes its own exhaust gas to reach the required floor pressure level, eliminating the need for additional capital equipment while maintaining fast startup performance.
Solution Approach 2:
The patent changes the pressure parameter dynamically during startup by first operating at a sub-floor pressure level to enable early steam flow, then allowing the exhaust gas to naturally raise the pressure to the required floor level. This parameter change approach replaces expensive mechanical pressurization systems with a controlled pressure transition strategy.
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 approach enables faster steam availability and reduced start-up times for combined cycle plants, minimizing fuel burn and emissions while avoiding the costs associated with traditional methods, such as mechanical means or specialized equipment.
Implementation Method 1
pressurizing the HRSG steam circuit to the selected lowest pressure level
Implementation Method 2
As pressure builds the only steam flow is from condensation inside steam pipes and HRSG tubing
Implementation Method 3
determining a calculated steam velocity level for each of the plurality of candidate pressure levels
Data Source
AI summary
A method for adjusting startup floor pressure levels of HRSG steam circuits is implemented by a pressure controlling computing device including a processor and a memory. The method includes receiving a plurality of measured plant operating values associated with a HRSG steam circuit, identifying a plurality of candidate pressure levels for use in pressurizing the HRSG steam circuit, determining a calculated steam velocity level for each of the plurality of candidate pressure levels, identifying a steam velocity limit for a steam piping section of the HRSG steam circuit, selecting a lowest pressure level of the plurality of candidate pressure levels, wherein the lowest pressure level is associated with a determined calculated steam velocity level that does not exceed the identified velocity limit, and pressurizing the HRSG steam circuit to the selected lowest pressure level.


