The subject matter disclosed herein relates generally to heat recovery steam generators (HRSG) and, more specifically, to fluid flow into drums within the HRSG system.
An HRSG may be used as part of a combined cycle power plant, which includes both a gas turbine and a steam turbine. The gas turbine generates hot exhaust gases, which are used by the HRSG to generate steam to drive the steam turbine. The HRSG may include a number of drums to facilitate the heat exchange between the exhaust gas and water. Unfortunately, heating within each drum may create steam bubbles that can cause shrinking and swelling conditions to occur within the drum. Shrinking may be caused by an increase in the feed water supplied to the drum, which lowers the temperature within the drum and can cause steam bubbles to collapse. Collapsing bubbles in turn causes a drop in fluid level even though feed water is being added to the drum. Shrinking may also be caused when there is a sudden decrease in the amount of steam drawn from the drum which results in a sudden increase in pressure within the drum. Swelling conditions include a reversal of the shrinking conditions (i.e., a decrease in the feed water supply or a sudden increase in the amount of steam drawn from the drum) which results in a decrease in pressure within the drum. Swelling conditions may cause an increase in the number and size of the bubbles within the fluid in the drum, which increases the apparent fluid level. Shrinking and swelling conditions can potentially cause plant down time when fluid levels rise too high or drop too low.
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a system includes a heat recovery steam generator (HRSG) having an economizer disposed along a fluid flow path, and a drum disposed along the fluid flow path downstream of the economizer The drum is configured to contain and heat a fluid. The heat recovery steam generator also includes a drum level control module configured to modulate an amount of the fluid provided to the drum along the fluid flow path and a supplemental control module configured to control an amount of the fluid provided to the drum along the fluid flow path in a different manner than the drum level control module. The heat recovery steam generator also includes a drum level event controller configured to monitor a rate of change of a level of the fluid in the drum. If the rate of change is over a threshold value, then the drum level event controller is configured to send a signal to the supplemental control to modulate the amount of fluid provided to the drum. If the rate of change is less than or equal to the threshold value, then the drum level event controller is configured to send the signal to the drum level control module to modulate the amount of the fluid provided to the drum.
In a second embodiment, a method includes receiving, at a processor, a level rate of change of a fluid within a drum of a heat recovery steam generator. The method also includes determining, via the processor, whether the rate of change exceeds a threshold value. If the rate of change exceeds the threshold value, the method includes sending a signal to a supplemental control module to modulate an amount of the fluid provided to the drum along a fluid flow path. If the rate of change does not exceed the threshold value, the method includes sending the signal to a drum level control module to modulate an amount of the fluid provided to the drum along the fluid flow path. The supplemental control module and the drum level control module modulate the amount of the fluid provided to the drum differently.
In a third embodiment, a system includes a drum level event controller configured to receive a drum level rate of change of a fluid within a drum of a heat recovery steam generator and determine whether the rate of change exceeds a threshold value. If the rate of change exceeds the threshold value, the drum level controller is configured to respond by sending a signal to a supplemental control module to modulate an amount of the fluid provided to the drum along a fluid flow path. If the rate of change does not exceed the threshold value, the drum level controller is configured to respond by sending the signal to a drum level control module to modulate an amount of the fluid provided to the drum along the fluid flow path. The supplemental control module and the drum level control module modulate the amount of the fluid provided to the drum differently.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
The disclosed embodiments include systems and methods for more accurately responding to changes in the level of a drum (e.g., boiler drums, high pressure drums, intermediate pressure drums, etc.), such as a boiler drum of an HRSG system. As mentioned above, shrinking and swelling conditions may create an apparent fluid level within a drum that is not consistent with proper operation of the HRSG system 10. In response to these apparent fluid levels, without the disclosed embodiments, valve controllers may respond with an undesirable increase or decrease in the fluid flow. For example, during a shrinking condition, the apparent fluid level decreases due to collapsing steam bubbles, as explained above. A valve controller may, without the disclosed embodiments, respond to the apparent decrease in fluid level by increasing the amount of feed water provided to the drum. This increase in feed water may cause a rapid decrease in the temperature and pressure within the drum, which may cause undesirable operation of the plant. As another example, during swelling, steam bubbles may increase the apparent fluid level within the drum. The valve controller, without the disclosed embodiments, may respond with a decrease in the fluid flow provided to the drum. This situation may also cause rapid fluctuation in the temperature and pressure within the drum, which may also trigger a trip in the system 8, or part of the system 8. Without a pressure sensor within the drum, it is difficult to determine the actual fluid level and/or the mass of fluid within the drum. Therefore, an additional control that senses the rate of change of the drum level (e.g., surface level of the fluid within the drum) may be employed to decrease rapid fluctuations in the drum level caused by shrinking, swelling, or similar condition.
The additional control senses the rate of change of the drum level and sends signals to control valves and/or fluid flow paths that may convey fluid to the drum at different rates. In the embodiments below, two fluid flow paths are described that may convey fluid to the drum based on a controller sending a signal to one of two control modules. In other embodiments, more control modules may be employed. The two control modules control fluid flow along two flow paths. A first fluid flow path flows through an economizer and a first valve while a second fluid flow path may flow around the economizer to the drum, around the economizer back to the first fluid flow path, or around the valve to the drum or back to the first fluid flow path.
In certain embodiments, the system 8 may include a controller 28 having memory 31 including non-transitory readable media storing code or instructions executed by a processor 32. The controller 28 may include one or more control modules as described in detail below. The control modules may be used to control certain aspects of the system 8. For example, the controller 28 may send or receive signals 29 (e.g., feedback data) from one or more sensors 30 disposed in the HRSG 10. In certain embodiments, the sensors 30 may be disposed in one or more of the HP section 12, the IP section 14, or in the LP section 16. The controller 28 communicating with the sensors 30 may also control other sections of the system 8 or may be part of a larger network of controllers with sensors 30 within the gas turbine 22, the inlet section 18, the HRSG stack 24, or any combination thereof. The sensors 30 may measure various conditions or parameters of the HRSG 10, such as, but not limited to, a level of fluid within a drum, a temperature, a flow rate, a pressure, or any combination thereof. More specifically, the controller 28 may use the information received from the sensors 30 to generate and send signals 29 (e.g., control signals) to one or more components of the system 8.
The IP section 14 (e.g., heat exchangers, drum, valves, pumps, sensors, actuators) connects to the controller 28 at several connections throughout the IP section 14. The controller 28 includes a drum level control module 46 that is connected to the IP feed water control valve 42. The drum level control module 46 adjusts the control valve 42 in order to control the amount of fluid flow through the control valve 42. The drum level control module 46 may adjust the fluid flow based on a user input or based on feedback from the sensors 30 within the first fluid flow path 36 and/or within the IP drum 34. The IP drum 34 may also contain a sensor 30 that monitors the fluid level within the IP drum 34, the rate of change of the fluid level within the IP drum 34, or other characteristics of the IP drum 34. The sensors 30 communicate with a drum level event controller 48 so that the system 8 may react appropriately to maintain proper fluid level.
Rather than using a single flow (i.e., the first fluid flow 36 controlled by the drum level control module 46), the controller 28 in the illustrated embodiment uses a second fluid flow path 50 whereby feed water may flow from one part of the IP section 14 to another part. As illustrated in
In certain embodiments, the drum level event controller 48 sends a signal or signals to the drum level control module 46, the supplemental control module 54, or both based on the rate of change sensed by the sensors 30 of the fluid level within the IP drum 34. For example, if sensors 30 indicate that the rate of change of the fluid level in the IP drum 34 is over a threshold value, then the drum level event controller 48 sends a signal to the supplemental control module 54 to provide extra fluid flow through the supplemental control valve 52. On the other hand, if sensors indicate that the rate of change is less than the threshold value, then the drum level event controller 48 sends the signal to the drum level control module 46 which executes a normal drum level control of the fluid through the control valve 42. The threshold value is determined by the difference between the detected rate of change via sensors, and the normal rate of change expected for the current operation. For example, in one embodiment, the threshold value of the rate of change is two times the normal rate of change, in which case the drum level event controller 48 sends the signal to the supplemental control module 54. In other embodiments, the threshold value is 1.5, 2.5, 3, 3.5, or other multiples of the normal rate of change. In still other embodiments, the drum level event controller 48 may respond to multiple threshold values that determine different types of signals that are sent to both the supplemental control module 54 and the drum level control module 46. One type of signal may initiate the supplemental control module 54 to open the supplemental control valve 52 to 20 percent of maximum flow. Another rate of change detected by the sensors 30 may cause the drum level control module 46 to send a signal to the supplemental control module 54 to open the supplemental control valve 52 to 50 percent, or 60 percent. Furthermore, the supplemental control module 54 may have a default condition such that the valve 52 is open to an intermediate flow level. In such a condition, responding to the signal from the drum level event controller 48 may include lowering the flow level (e.g., a default flow level is 50 percent open and response to the signal from the drum level event controller 48 lowers the flow to 25 percent). Thus, the amount of flow through the supplemental control valve 52 may be any percentage based on a determination by the drum level event controller 48. In the illustrated embodiment, the supplemental control module 54 delivers an amount of fluid along the second fluid flow path 50 that is different than the amount of fluid delivered along the first fluid flow path 36. This enables the controller 28 to respond to shrink and swell conditions without causing a plant trip.
Technical effects of the disclosed embodiments include controlling the fluid level within a drum by adjusting the mechanisms for introducing fluid into the drum. The controller 28 monitors the rate of change within the drum (e.g., IP drum 34) and sends a signal to different modules depending on that rate. If the rate of change of the fluid level is over the threshold value, then the drum level event controller 48 within the controller 28 may send the signal to the supplemental control module 54. This may alleviate the effects of shrinking and swelling conditions.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.