Threaded In-Line Orifice Assembly for Fast HRSG Flow Tuning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat recovery steam generators (HRSG) require precise tuning of steam pressures, temperatures, and flow rates, which can be time-consuming and costly due to the need for multiple iterations and potential damage to schedules and budgets, especially in drum-less systems where traditional replacement methods are cumbersome and costly.
Innovation Solution
The introduction of a simplified in-line orifice and adaptor assembly featuring a hex socket with external threading that can be easily inserted and removed, allowing for quick adjustment of flow rates without cutting or rewelding, enabling precise control of fluid flow without the need for hydro testing or chemical cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional orifice replacement methods are used in drum-less HRSG systems, then flow rate adjustment can be achieved, but the process becomes time-consuming and costly due to cutting and rewelding requirements
Solution Approach 1:
The orifice assembly is divided into separate components: the orifice plug and the adaptor. The adaptor remains permanently installed in the HRSG piping, while the orifice plug can be independently removed and replaced. This segmentation eliminates the need for cutting and rewelding, allowing quick replacement by simply unscrewing the old plug and screwing in a new one.
Solution Approach 2:
The orifice plug is designed with external threading that engages with internal threading in the adaptor, creating a dynamic, removable connection rather than a fixed welded joint. This allows the orifice plug to be easily adjusted, removed, or replaced without permanent modifications to the HRSG system, enabling rapid flow rate adjustments.
2Adaptability or versatility
If traditional orifice replacement methods are used, then flow rate adjustment is possible, but structural integrity may be compromised and costly weld repairs are required
Solution Approach 1:
By separating the orifice plug from the adaptor, the design allows flow rate adjustment without compromising the integrity of the main HRSG piping. The adaptor serves as a permanent, structurally sound mounting point, while the removable plug enables flexibility. This eliminates the need for repeated cutting and welding that would weaken the original piping structure.
Solution Approach 2:
The adaptor acts as an intermediary component between the HRSG piping and the orifice plug. It provides a threaded interface that allows easy replacement of the orifice plug while maintaining the structural integrity of the original piping. The adaptor absorbs the mechanical stresses and connections, protecting the main system from damage during orifice replacements.
3Manufacturing precision
If multiple fine-tuning iterations are performed during build and commissioning, then precise operating conditions can be achieved, but schedules and budgets are adversely impacted
Solution Approach 1:
The removable orifice plug with threaded connection enables rapid iteration during commissioning. Different orifice plugs with varying flow coefficients can be quickly swapped by simply unscrewing one plug and screwing in another, allowing multiple fine-tuning iterations without time-consuming welding operations. This maintains manufacturing precision while significantly improving commissioning productivity.
Solution Approach 2:
The system allows easy change of flow parameters by replacing the orifice plug with different specifications. During commissioning, precise operating conditions can be achieved through multiple iterations by selecting and installing different orifice plugs with appropriate flow coefficients, without impacting schedule or budget due to the simplicity of replacement.
Data Source
AI summary
An adaptor assembly includes: an adaptor piece including: a forged outer wall defining a substantially cylindrical shape; a through hole disposed at a top portion of the adaptor piece, the through hole defining an adaptor center cavity; a threaded portion disposed beneath the through hole; and a second hole disposed beneath the threaded portion. The adaptor assembly includes a hex socket including external threading. A diameter of the through hole is smaller than a diameter of the second hole. The hex socket is inserted through the second hole and screwed into the adaptor piece such that the external threading mates with the threaded portion.