The present disclosure relates generally to a heat recovery steam generator (HRSG), and more particularly, to a tube for controlling flow in an HRSG having inclined tubes for heat exchange.
A heat recovery steam generator (HRSG) is an energy recovery heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process (cogeneration) or used to drive a steam turbine (combined cycle). Heat recovery steam generators generally comprise four major components—the economizer, the evaporator, the superheater and the water preheater. In particular, natural circulation HRSG's contain evaporator heating surface, a drum, as well as the necessary piping to facilitate the appropriate circulation ratio in the evaporator tubes. A once-through HRSG replaces the natural circulation components with once-through evaporator and in doing so offers in-roads to higher plant efficiency and furthermore assists in prolonging the HRSG lifetime in the absence of a thick-walled drum.
An example of a once through evaporator heat recovery steam generator (HRSG) 100 is shown in the
Due to design considerations, it is often the case that thermal head limitations necessitate an additional heating loop in order to achieve superheated steam at the outlet. Often times additional provisions are needed to remix water/steam bubbles prior to re-entry into the second heating loop, leading to additional design considerations. In addition, there exists a gas-side temperature imbalance downstream of the heating surface as a direct result of the vertically arranged parallel tubes. These additional design considerations utilize additional engineering design and manufacturing, both of which are expensive. These additional features also necessitate periodic maintenance, which reduces time for the productive functioning of the plant and therefore result in losses in productivity. It is therefore desirable to overcome these drawbacks.
Disclosed herein is a once-through evaporator comprising an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers.
Disclosed herein too is a method comprising discharging a working fluid through a once-through evaporator; where the once-through evaporator comprises an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers; discharging a hot gas from a furnace or boiler through the once-through evaporator; and transferring heat from the hot gas to the working fluid.
Referring now to the Figures, which are exemplary embodiments, and wherein the like elements are numbered alike:
Disclosed herein is a heat recovery steam generator (HRSG) that comprises a single heat exchanger or a plurality of heat exchangers whose tubes are arranged to be “non-vertical”. By non-vertical, it is implied the tubes are inclined at an angle to a vertical. By “inclined”, it is implied that the individual tubes are inclined at an angle less than 90 degrees or greater than 90 degrees to a vertical line drawn across a tube. In one embodiment, the tubes can be horizontal in a first direction and inclined in a second direction that is perpendicular to the first direction. These angular variations in the tube along with the angle of inclination are shown in the
The section (or plurality of sections) containing the horizontal tubes is also termed a “once-through evaporator”, because when operating in subcritical conditions, the working fluid (e.g., water, ammonia, or the like) is converted into vapor gradually during a single passage through the section from an inlet header to an outlet header. Likewise, for supercritical operation, the supercritical working fluid is heated to a higher temperature during a single passage through the section from the inlet header to the outlet header.
The once-through evaporator (hereinafter “evaporator”) comprises parallel tubes that are disposed non-vertically in at least one direction that is perpendicular to the direction of flow of heated gases emanating from a furnace or boiler.
The
The evaporator 200 comprises an inlet manifold 202, which receives a working fluid from an economizer (not shown) and transports the working fluid to a plurality of inlet headers 204(n), each of which are in fluid communication with vertical tube stacks 210(n) comprising one or more tubes that are substantially horizontal. The fluid is transmitted from the inlet headers 204(n) to the plurality of tube stacks 210(n). For purposes of simplicity, in this specification, the plurality of inlet headers 204(n), 204(n+1) . . . and 204(n+n′), depicted in the figures are collectively referred to as 204(n). Similarly the plurality of tube stacks 210(n), 210(n+1), 210(n+2) . . . and 210(n+n′) are collectively referred to as 210(n) and the plurality of outlet headers 206(n), 206(n+1), 206(n+2) . . . and 206(n+n′) are collectively referred to as 206(n).
As can be seen in the
The hot gases from a source (e.g., a furnace or boiler) (not shown) travel perpendicular to the direction of the flow of the working fluid in the tubes 210. With reference to the
As seen in the
The terms ‘n′’ is an integer value, while “n′” can be an integer value or a fractional value. n′ can thus be a fractional value such as ½, ⅓, and the like. Thus for example, there can therefore be one or more fractional inlet headers, tube stacks or outlet headers. In other words, there can be one or more inlet headers and outlet headers whose size is a fraction of the other inlet headers and/or outlet headers. Similarly there can be tube stacks that contain a fractional value of the number of tubes that are contained in the other stack. It is to be noted that the valves and control systems having the reference numeral n′ do not actually exist in fractional form, but may be downsized if desired to accommodate the smaller volumes that are handled by the fractional evaporator sections. In one embodiment, there can be at least one or more fractional tube stacks in the once-through evaporator. In another embodiment, there can be at least two or more fractional tube stacks in the once-through evaporator.
In one embodiment, the once-through evaporator can comprise 2 or more inlet headers in fluid communication with 2 or more tube stacks which are in fluid communication with 2 or more outlet headers. In one embodiment, the once-through evaporator can comprise 3 or more inlet headers in fluid communication with 3 or more tube stacks which are in fluid communication with 3 or more outlet headers. In another embodiment, the once-through evaporator can comprise 5 or more inlet headers in fluid communication with 5 or more tube stacks which are in fluid communication with 5 or more outlet headers. In yet another embodiment, the once-through evaporator can comprise 10 or more inlet headers in fluid communication with 10 or more tube stacks which are in fluid communication with 10 or more outlet headers. There is no limitation to the number of tube stacks, inlet headers and outlet headers that are in fluid communication with each other and with the inlet manifold and the outlet manifold. Each tube stack is sometimes termed a bundle or a zone.
The
Disposed on an upper surface of the once-through evaporator are rods 306 that contact the plates 250. Each rod 306 supports the plate and the plates hang (i.e., they are suspended) from the rod 306. The plates 250 (as detailed above) are locked in position using clevis plates. The plates 250 also support and hold in position the respective tube stacks 210(n). In this
Since each rod 306 holds or supports a plate 250, the number of rods 306 are therefore equal to the number of the plates 250. In one embodiment, the entire once-through evaporator is supported and held-up by the rods 306 that contact the horizontal rods 304. In one embodiment, the rods 306 can be tie-rods that contact each of the parallel horizontal rods 304 and support the entire weight of the tube stacks. The weight of the once-through evaporator is therefore supported by the rods 306.
Each section is mounted onto the respective plates and the respective plates are then held together by tie rods 306 at the periphery of the entire tube stack. A number of vertical plates support these horizontal heat exchangers. These plates are designed as the structural support for the module and provide support to the tubes to limit deflection. The horizontal heat exchangers are shop assembled into modules and shipped to site. The plates of the horizontal heat exchangers are connected to each other in the field.
The
The
The tubes are in a zig-zag arrangement (as can be seen in the upper left hand of the
The
The
The angle θ1 can vary from 55 degrees to 88 degrees, specifically from 60 degrees to 87 degrees, and more specifically 80 degrees to 86 degrees. The inclination of the tubes in one or more directions provides a space 270 between the duct wall 280 and the rectangular geometrical shape that the tube stack would have occupied if the tubes were not inclined at all. This space 270 may be used to house control equipment. This space may lie at the bottom of the stack, the top of the stack or at the top and the bottom of the stack. Alternatively, this space can be used to facilitate counterflow of the hot gases in the tube stack.
In one embodiment, this space 270 can contain a fractional stack, i.e., a stack that is a fractional size of the regular stack 210(n) as seen in the
In the
The
This arrangement is advantageous because operational turn down is possible. However, it is to be noted that the heating surface is less efficient and can lead to an additional pressure drop on the side at which the hot gases first contact the tube stack. This in-line arrangement results in added tubes and exacerbates draining concerns.
The
In the
In the aforementioned arrangements (i.e., the staggered or the in-line arrangement variations) the hot gases from the furnace may travel through the tube stack without any directional change or they can be redirected across the heating surface via some form of flow controls and/or gas path change.
The staggered counterflow horizontally arranged heating surface (
For inline counter flow horizontally arranged heating surface (
It is to be noted that this application is co-filed with U.S. Patent Applications having Ser. Nos. 61/587,230, 13/744,094, 13/744,104, 13/744,121, 61/587,402, 13/744,112, and 13/744,126, the entire contents of which are incorporated by reference herein.
Maximum Continuous Load” denotes the rated full load conditions of the power plant.
“Once-through evaporator section” of the boiler used to convert water to steam at various percentages of maximum continuous load (MCR).
“Approximately Horizontal Tube” is a tube horizontally orientated in nature. An “Inclined Tube” is a tube in neither a horizontal position or in a vertical position, but dispose at an angle therebetween relative to the inlet header and the outlet header as shown.
It will be understood that, although the terms “first,” “second,” “third” etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, “a first element,” “component,” “region,” “layer” or “section” discussed below could be termed a second element, component, region, layer or section without departing from the teachings herein.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, singular forms like “a,” or “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.
Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower,” can therefore, encompasses both an orientation of “lower” and “upper,” depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Exemplary embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.
The term and/or is used herein to mean both “and” as well as “or”. For example, “A and/or B” is construed to mean A, B or A and B.
The transition term “comprising” is inclusive of the transition terms “consisting essentially of” and “consisting of” and can be interchanged for “comprising”.
While this disclosure describes exemplary embodiments, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the disclosed embodiments. In addition, many modifications can be made to adapt a particular situation or material to the teachings of this disclosure without departing from the essential scope thereof. Therefore, it is intended that this disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure.
This disclosure claims priority to U.S. Provisional Application No. 61/587,332 filed Jan. 17, 2012, U.S. Provisional Application No. 61/587,428 filed Jan. 17, 2012, U.S. Provisional Application No. 61/587,359 filed Jan. 17, 2012, and U.S. Provisional Application No. 61/587,402 filed Jan. 17, 2012, the entire contents of which are all hereby incorporated by reference.
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