The present invention relates to an exhaust heat recovery boiler (hereinafter, referred to occasionally as HRSG) to be used for a combined cycle power plant, more specifically, an exhaust heat recovery boiler construction method (modularization method) and a heat exchanger tube panel module structure to be used with this method.
A combined cycle power plant using a gas turbine has a high heat efficiency in comparison with a thermal power plant using a coal-fired boiler, and the amount of SOx and soot and dust generated from the combined cycle power plant is small since it uses natural gas mainly as fuel, and therefore, the burden on exhaust gas purification is small, whereby the combined cycle power plant has gained attention as a power plant with great future potential. Furthermore, the combined cycle power plant is excellent in load responsibility, and has gained attention simultaneously as a power generation method which can rapidly change its power output in accordance with power demands, suitable for high-frequency start and stop (daily start and daily stop).
The combined cycle power plant comprises main components including an HRSG for generating steam by using a power generating gas turbine and exhaust gas from the gas turbine and a steam turbine for generating power by using steam obtained by the HRSG.
Equipment including the HRSG that compose the combined cycle power plant have small capacities in comparison with equipment composing a high-capacity thermal power plant, and can be transported after being assembled up to a stage close to completion within a plant equipment manufacturing factory, and in this case, installation on site is comparatively easy. Therefore, installation is completed in a short period in comparison with high-capacity equipment composing the thermal power plant.
However, even under these circumstances, the HRSG is not small in size, and its installation requires enormous labor and time. For example, for conventional installation of an HRSG, a bundle 3 of a necessary number of heat exchanger tubes each of which includes one hundred and several tens of heat exchanger tubes and headers as one unit are transported to a construction site, and heat exchanger tube panels are suspended for each unit from support beams provided on the ceiling of the HRSG casing constructed in advance at a construction site. Such work of suspending thousands or ten of thousands of heat exchanger tubes at a high place is not only dangerous but also results in an extended work period and high construction costs.
Therefore, a technical development has been strongly demanded which makes the construction of an HRSG easy by dividing the heat exchanger tube bundle 3 of the HRSG into several modules and modularizing the equipment composing the HRSG so that the modules are completed as one unit within a manufacturing factory and installation is completed by only assembling the unit.
Particularly, considering the circumstances that supply of HRSG construction parts and securing of experienced construction personnel outside Japan are difficult, the modularization method is very advantageous in which, within a domestic equipment manufacturing factory having a technical capacity necessary for manufacturing equipment composing an HRSG, a full management system for quality control or process management, etc., and a large number of skilled personnel, the equipment is completed as part products divided into a plurality of modules, transported to the site and assembled. Particularly, development of a method in which an HRSG whose capacity is comparatively great among equipment composing a combined cycle power plant is manufactured as a plurality of divided modules in advance in a factory and the modules are assembled at the HRSG construction site has been demanded.
An object of the invention is to provide an advantageous HRSG construction method in which components of an exhaust heat recovery boiler are manufactured and divided into a plurality of modules in a factory and then the modules are transported to the site and assembled, wherein heat exchanger tube panel modules are employed in this method.
Another object of the invention is to provide an HRSG construction method which prevents heat exchanger tube panels from being damaged during transportation, reduces transportation costs simultaneously, and reduces members to be wasted after installation, and heat exchanger tube modules to be used in this method.
The present invention provides a construction method for an exhaust heat recovery boiler which generates steam by arranging a heat exchanger tube bundle 3 within a casing 1 that forms a gas duct for almost horizontal flows of exhaust gas, wherein modules 25 each of which is obtained by housing a member including heat exchanger tube panels 23 each comprising a plurality of heat exchanger tubes 6 and corresponding headers 7 and 8, an upper casing 20 provided above the heat exchanger tube panel 23, and support beams 22 for the heat exchanger tube panel provided on the upper surface of the upper casing 20 in a transportation frame 24 that is formed of a rigid body and used only during transportation, are manufactured by a necessary size and number according to design specifications of the exhaust heat recovery boiler, structural members for supporting the modules 25, including ceiling part support beams 33 and 34 and side casings 1a and 1b and a bottom casing 1c of the exhaust heat recovery boiler except for the ceiling part are constructed in advance at a construction site, and at the construction site of the exhaust heat recovery boiler, surfaces of each module 25 which will be set perpendicular to the gas flow are set to the upper and lower sides and each module is erected together with the transportation frame 24, each module 25 is extracted from the inside of the transportation frame 24, and the respective modules 25 are suspended from above between adjacent ceiling part support beams 33, whereby the heat exchanger tube panel support beams 22 of respective modules 25 are disposed at the set heights of the ceiling part support beams 33 and the support beams 22 and 33 are connected and fixed to each other via connecting steel plates 36, 39, and 40.
In the above-mentioned exhaust heat recovery boiler construction method, at a construction site of the exhaust heat recovery boiler, it is possible that surfaces of each module 25 which will be set perpendicular to the gas flow are set to the upper and lower sides and the module is temporarily fixed onto a standing jig 37, the standing jig 37 with the module 25 placed is propped up so that the lengthwise direction of the standing jig 37 is turned to be vertical at a position adjacent to the side casing 1a or 1b of the exhaust heat recovery boiler by a crane 42, and next, surfaces of the module 25 which will be set perpendicular to the gas flow are arranged so as to be parallel with the side casing 1a or 1b of the exhaust heat recovery boiler and the standing jig 37 is temporarily fixed to the side casing 1a or 1b, and the target to be lifted by the crane 42 is changed into the heat exchanger tube panel support beams 22 of the module 25 placed inside the standing jig 37 temporarily fixed to the side casing 1a or 1b, the module 25 is lifted so as to come off the standing jig 37, and the module 25 lifted by the crane 42 is suspended from above between adjacent ceiling part support beams 33 of the supporting structural members of the exhaust heat recovery boiler.
Furthermore, in the exhaust heat recovery boiler construction method, the following method may be employed in which the heat exchanger tube panel support beams 22 of each module 25 are set at the set heights of the ceiling part support beams 33 and both support beams 22 and 33 are connected and fixed to each other via first connecting steel plates 36, and thereafter, gaps created between the upper casing 20 of each module 25 and the ceiling part support beams 33 are closed by a second steel plate 39, and the upper casing 20, the ceiling part support beams 22, and the second steel plate 39 are connected by means of welding.
Furthermore, it is possible that a heat insulator 13 is provided below the upper casing 20 of each module 25, the upper headers 7 are provided with connecting pipes for circulation of steam or water, and header supports 11 are provided so as to be suspended from the heat exchanger tube panel support beams 22 between the upper casing 20 and the upper headers 7 of each module 25.
Furthermore, the invention provides heat exchanger tube panel modules 25 for construction of an exhaust heat recovery boiler, wherein one module unit comprises the heat exchanger tube module 25 which includes a heat exchanger tube panel module comprising a member including a heat exchanger tube panel 23 which comprises a plurality of heat exchanger tubes and corresponding headers 7 and 8 for the heat exchanger tubes 6, an upper casing 20 provided above the heat exchanger tube panel 23, and support beams 22 for the heat exchanger tube panel provided on the upper surface of the upper casing 20, and a transportation frame 24 that houses the module and is used only during transportation and formed of a rigid body, and the heat exchanger tube panels 23 of the one module unit are provided with vibration isolating supports 18 at predetermined intervals to prevent contact between heat exchanger tubes 6 adjacent to each other in a direction crossing the lengthwise direction of the plurality of heat exchanger tubes.
In the above-mentioned heat exchanger tube panel module 25, a shake preventive fixing member 32 to be disposed between the end of the vibration isolating support 18 and the transportation frame 24 is provided.
In the invention, in the heat exchanger tube panel module 25 obtained by housing a member including the heat exchanger tube panels 23 each including a plurality of heat exchanger tubes 6 and headers 7 and 8 for the heat exchanger tubes, the upper casing 20 provided above the heat exchanger tube panel 23, and the support beams 22 for the heat exchanger tube panel provided on the upper surface of the upper casing 20 inside the transportation frame 24, the heat exchanger tube panels 23 can be fixed by the transportation frame 24 and are prevented from being damaged due to shaking during transportation.
Particularly, by providing shake preventive fixing members 32 between the vibration isolating supports 18, 26, 27, 32 and the transportation frame 24, the effect of preventing damage due to shaking during transportation is increased.
Furthermore, since the supporting structural members including the ceiling part support beams 33 and 34 and the side casings 1a and 1b and the bottom casing 1c of the HRSG except for the ceiling part are constructed in advance at the HRSG construction site, by using the standing jig 37 and the crane 42, the heat exchanger tube panel module 25 is detached from the transportation frame 24 and the heat exchanger tube panel support beams 22 of each module 25 are arranged at the set heights of the ceiling part support beams 33 by being suspended from above between adjacent ceiling part support beams 33, and the support beams 22 and 33 are connected and fixed via the connecting steel plates 36, 39, and 40.
As mentioned above, the heat exchanger tube panel modules 25 are manufactured in a manufacturing factory, and then the modules 25 are transported to the construction site and installed on site, whereby installation of the heat exchanger tube panels 23 is completed along with the casing 1 for an HRSG, the dangerous construction work at the upper side inside the casing 1 of the HRSG is eliminated, setting up of scaffolds and dismounting thereof become unnecessary, and the heat exchanger tube panels 23 can be easily installed in the casing 1 of the HRSG within a short period of time, so that the HRSG can be constructed within a short work period.
A modularization method of an exhaust heat recovery boiler as an embodiment of the invention is described with reference to the drawings.
A heat exchanger tube panel 23 of the exhaust heat recovery boiler comprises, as shown in
In an HRSG for a combined cycle power plant whose steam temperature is of a 1300° C. class, the panels are divided into two or three modules 25 in the width direction of the gas duct (direction orthogonal to the gas flow), and divided into six through twelve modules 25 in the gas flow direction due to the layout of the heat exchanger tube bundle and transporting restrictions, and the modules 25 have different sizes in accordance with the layout positions inside the HRSG in some cases. The size of one module 25 is, for example, 26 m in length, 3 through 4.5 m in width, and 1.5 through 4 m in height.
In each module 25, three through eight panels of fin-wound heat exchanger tube panels 23, upper connecting pipes 9 in which heated fluid circulates between the module and the headers of another adjacent module 25, upper casings 20, heat insulators 21 attached to the inner surfaces of the upper casings 20 and inner casings 19 are installed so as to satisfy the size of a completed product after installation at a construction site, and furthermore, on the upper casings 20, a predetermined number of heat exchanger tube panel support beams 22 formed of wide flange beams are attached, and supports 11 for supporting the upper headers 7 are provided inside the upper casings 20 corresponding to the support beams 22. The above-mentioned parts are attached so as to be enclosed by the transportation frame 24 to form one module 25.
The heat exchanger tube panels 23 to be arranged inside the HRSG casing 1 are only suspended and supported by the support beams 22 attached to the upper casings 20, and if they are not fixed by the transportation frame 24, they may be damaged due to shaking during transportation.
In this embodiment, as shown in
Furthermore, it is also possible that a shake preventive fixing member having a plate with a length corresponding to the gap between the transportation frame 24 and the end of the vibration isolating support 18 is welded to both the transportation frame 24 and the vibration isolating support 18, and this fixing member is cut after transportation although this is not shown.
Furthermore, it is also possible that a timber plate with a thickness corresponding to the gap between the transportation frame 24 and the end of the vibration isolating support 18 is inserted into this gap, and after transportation, this plate is extracted.
Moreover, it is still also possible that a filling material such as sand, a gel material, or the like is filled in necessary portions of the heat exchanger tube panels 23 inside the transportation frame 24, and after transportation, the filling material is extracted.
Furthermore, it is also possible that the heat exchanger tube panels 23 are prevented from being damaged during transportation by a shake preventive fixing member 32 with a pair of rods 31 whose widths are changeable as shown in
The upper casings 20 inside the modules 25 are casing members which form the ceiling part of the HRSG casing 1 by joining the upper casings 20 of adjacent modules 25, and as shown in
Ceiling part support beams 33 and 34 that simultaneously serve as supporting members formed of wide flange beams for joining the upper casings 20 of the respective modules 25 are provided in advance in a lattice pattern at the ceiling surface of the casing 1 at the construction site.
The modules 25 that have arrived at the HRSG construction site are successively inserted into the opening of the casing 1 between the support beams 33 and 34 of the ceiling part of the casing 1 from above, however, before this operation, each module 25 that has arrived at the site is placed on the module standing jig 37 (
At the set location of the standing jig 37, the standing jig 37 is disposed so that the lengthwise direction thereof is along the lengthwise direction of the HRSG casing 1, that is, the gas duct of the HRSG. Therefore, as shown in the HRSG side view of
Thereby, as shown in
a) is a side view (sectional view along A-A line of
As shown in
Thereby, by installing the heat exchanger tube panel modules 25 on site, installation of the heat exchanger tube bundle is completed along with the HRSG casing 1. Furthermore, in this embodiment, since dangerous construction work at the upper side inside the casing 1 of the HRSG is eliminated, setting up of scaffolds and dismounting thereof also become unnecessary, and the heat exchanger tube panels 23 can be easily installed into the casing 1 of the HRSG in a short period of time, so that the HRSG can be constructed within a short work period.
Furthermore, only the heat exchanger tube panels 23 arranged in parallel in the gas path width direction of the exhaust heat recovery boiler of an embodiment of the invention are shown in the perspective view of
Both side surfaces of each heat exchanger tube plate panel 23 are provided with baffle plates 45, and these prevent short pass of gas from the gap between the heat exchanger tube panel 23 and the casing 1, however, the gaps between the heat exchanger tube panels 23 arranged in parallel in the gas path width direction of the exhaust heat recovery boiler as in this embodiment cannot be filled up by only the baffle plates 45. The reason for this is that provision of the gap between the adjacent heat exchanger tube panels 23 is necessary for the installation work of the heat exchanger tube panels 23 and thermal elongation of the panels 23.
If the gap is left as it is, gas passes through the gap, and as a result, the gas amount to pass through the heat exchanger tube panels 23 is reduced and the amount of recovered heat is lowered. Therefore, conventionally, after installation of the heat exchanger tube panels 23, in the gap between the heat exchanger tube panels 23, as shown in the plan view of
Therefore, in this embodiment, gas short pass preventive plates 46 are attached in advance in the factory, etc., to the baffle plates 45 of one of adjacent heat exchanger tube panels 23 at positions corresponding to the gas inlet and gas outlet of the respective heat exchanger tube panels 23 and brought into the construction site, and the heat exchanger tube panel 23 attached with the gas short pass preventive plates 46 is installed first. One side surface of the rectangular gas short pass preventive plate 46 is attached to the baffle plate 45, and the opposite side surface is left free.
After the heat exchanger tube panel 23 attached with the gas short pass preventive plates 46 is installed at a construction site, the other adjacent heat exchanger tube panel 23 without the gas short pass preventive plates 46 arranged in parallel is installed, and at this point, the other heat exchanger tube panels 23 are installed so that the gas short pass preventive plates 46 are in contact with the baffle plates 45 of the opposite heat exchanger tube panel 23.
Thereby, when gas flows, the free side surfaces of the gas short pass preventive plates 46 come into pressure-contact with the baffle plates 45 of the opposite heat exchanger tube panel 23 at the gas inlet side, the gap between the two heat exchanger tube panels 23 is eliminated, and gas short pass is prevented.
Furthermore, when the free side surfaces of the gas short pass preventive plates 46 are folded, the gas flow is efficiently trapped into the folded portions, so that the gas short pass preventive plates 46 are more securely pressed against the baffle plates 45 of the opposite heat exchanger tube panels 23, whereby the gap is eliminated and gas short pass is reliably prevented.
As mentioned above, by attaching in advance the gas short pass preventive plates 46 to the baffle plates 45 provided on both side surfaces of each heat exchanger tube panel 23 at the equipment factory, etc., it becomes unnecessary to set scaffolds for attachment works at the HRSG construction site, and this shortens the installation work period of the gas short pass preventive plates 46 and secures safety in the installation work.
In the invention, by employing a construction in which a part (module frames 24 and 25) of strength members including main columns 33 and main beams 34 of an HRSG are commonly used as components of the heat exchanger tube panel modules 20, in a case where the heat exchanger tube bundle modules 20 of the exhaust heat recovery boiler are installed at a construction site, a structure with high installation workability at the HRSG construction site can be applied to joint portions between the modules 20 and between the modules 20 and the strength members of the HRSG.
Furthermore, the bottom beams 36 as strength members set in advance at the HRSG construction site are made wider than the main columns 33, whereby the installation work labor of the heat exchanger tube panel modules 20 can be reduced, the construction process of the combined cycle power plant can be rationalized, and the local installation costs can be reduced.
Furthermore, after construction of the HRSG, the module frames 24 and 25 serve as a part of the strength members of the HRSG such as the main columns 33 and the main beams 34, so that it is advantageous that members to be scrapped after construction are virtually nil.
Furthermore, since shake preventive fixing members are provided between the vibration isolating supports 18 arranged at predetermined intervals and the casing 1 to prevent contact between adjacent heat exchanger tubes 6 during transportation of the heat exchanger tube panel modules 20, the heat exchanger tube panel modules 20 can be prevented from being damaged during transportation, whereby transportation of the heat exchanger tube panel modules 20 to a remote site becomes easy.
Furthermore, between two heat exchanger tube panels 23 adjacent in the gas path width direction (direction orthogonal to the gas flow), a gas short pass preventive plate 46 is provided on one side surface of which is connected to the baffle plate 45 of one of the heat exchanger tube panels 23 and the other side surface of which comes into contact with the baffle plate 45 of the other heat exchanger tube panel 23, and in particular, by folding the side surface of the gas short pass preventive plate 46 which comes into contact with the baffle plate 45 of the heat exchanger tube panel 23 toward the upstream side inside the gas duct, gas short pass between the two heat exchanger tube panels 23 is prevented, whereby heat retained in gas can be efficiently recovered.
Furthermore, by attaching in advance one-side surfaces of the gas short pass preventive plates 46 to the baffle plates 45 of the heat exchanger tube panels 23 on one side, the heat exchanger tube panels 23 with the gas short pass preventive plates 46 can be set without internal furnace scaffolds at the HRSG construction site, and this shortens the installation work period and is preferable in terms of safety of the installation work since works at high locations are eliminated.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP03/09657 | 7/30/2003 | WO | 00 | 1/4/2006 |
Publishing Document | Publishing Date | Country | Kind |
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WO2005/012790 | 2/10/2005 | WO | A |
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Number | Date | Country |
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4-124501 | Apr 1992 | JP |
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2003-222302 | Aug 2003 | JP |
Number | Date | Country | |
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20070119388 A1 | May 2007 | US |