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Cold starts: No pressure on steam system, prior shutdown greater than 24 to 30 hours.
Warm starts: High-pressure steam pressure is typically 60 to 200 psi, after a shutdown of 10 to 20 hours. Hot starts: High-pressure steam is typically greater than 500 psi, after a shutdown of 8 to 10 hours.
1. Producing condensate. This figure illustrates that when the combustion turbine exhaust temperature (HRSG inlet temperature) during a cold air purge is below the saturation temperature, enormous quantities of condensate are formed inside the HRSG that must be removed through vents before startup can continue. Source: Tetra Engineering Group Inc.
For cold starts, the time required for purge adds to the total time required for starting the unit, from pushing the start button through synchronization and ramp-up to full load. Added time is required during warm and hot starts as well, but in these two situations the purge puts relatively cold airflow through a warm or hot HRSG and its upstream and downstream duct work. This relatively cold purge air quenches the relatively hot HRSG and its ducting, which produce lower metal and water temperatures and, thus, steam pressure. As long as the temperature of the incoming purge air is less than the saturation temperature of the highpressure steam system, the system loses heat and superheater panels act as large condensers for the trapped condensed steam (Figure 2).
2. Accumulating condensate. During the purge period (shown in Figure 1), water can accumulate inside the HRSG superheater panels that must be vented. Source: Tetra Engineering Group Inc.
The amount of condensate produced can be quite large. This condensate must be removed prior to loading the CT to avoid water transport to the steam turbine or other components. Excessive condensate in the HRSG can cause blockage of steam flow through tubes, thermal distortion and shock, and many other problems. Draining the condensate in a timely fashion requires drain systems with adequately sized pipes, valves, and discharge. The drains also act to reduce operating pressures and, thus, temperatures in the HRSG steam systems. In daily or two-shift cycling CCs, the thermal impact of the purge cycle can result in damage to pressure parts, causing leaks and a reduction in the remaining life of parts (Figure 3).
3. Draining condensate. Many combined cycle plant owners have retrofitted their superheater panels with high-capacity drains and added multiple drain connections to speed condensate removal and therefore quicken plant startup. Source: Tetra Engineering Group Inc.
Over the past few years, HRSG purge issues have been extensively discussed at industry conferences. Somein particular, a large segment of CC suppliers and operatorssuggest eliminating the purge requirement on cycling units. However, the safety need for eliminating
combustible gases remains. A concept for modifying the purge requirements to credit prior purges for cycling CCs was first introduced to the NFPA Technical Committee for Heat Recovery Steam Generators in 2003. The NFPA Boiler and Combustion Systems Hazards Code Committee established a task group in 2006 to pursue the idea and to enable CC operators to safely implement procedures that provide for a fast-start capability. The change in the code was finally issued in the 2011 Edition of NFPA 85 as the Combustion Turbine Purge Credit.
System 1 for gaseous fuels: Use triple block and vent valves with continuous monitoring of valve position, pressures in the two double block and vent valve pipe sections, and block valve validation for leak tightness by a valve-proving system (Figure 4).
4. Purge system 1. Gaseous fuel triple block and double vent valve arrangement. Source: NFPA 85, Figure A.8.8.4.6.1
System 2 for gaseous fuels: Use triple block and vent valves with pressurized pipe sections. The two pipe sections are filled with an inert gas or air at sufficient pressure to prevent fuel gas from entering. Continuous monitoring of valve positions and pressurized pipe section pressures is required (Figure 5).
5. Purge system 2. Gaseous fuel with pressurized pipe section. Source: NFPA 85, Figure A.8.8.4.6.2
System 3 for liquid fuels: Use a triple block and double drain valve arrangement filled with pressurized inert gas or air. Continuous monitoring of valve positions and pressurized pipe section pressures is required (Figure 6).
6. Purge system 3. Liquid fuel with pressurized pipe section. Source: NFPA 85, Figure A.8.8.4.6.3
as optimized high-pressure steam drums) and touts a 13- to 15-minute faster response than a typical CC plant. For older plants, greater startup time savings are possible. Another tangible benefit is greater HRSG reliability and longevity. Daily cycling a CC plant typically means 150 to 250 starts per year. We estimate a 60% to 80% reduction in the hot/warm start contribution to steam drum fatigue (downcomer and steam outlet nozzles) and the hot/warm start contribution to superheater fatigue is reduced by a factor of 10. Much of these reduced fatigue estimates are a result of lower condensate production caused by unnecessary cold air purges and consequent thermal damage. Exhaust gas path components, such as perforated plates and flow vanes, also see less fatigue damage. Purge reduction also lowers the use of electricity for startup (and purging), burns less natural gas, and reduces water consumption. David S. Moelling, PE (dave.moelling@tetra-eng.com) is chief engineer and Peter S. Jackson, PE (pjackson@tetraengineeringgroup.com) is director, field services for Tetra Engineering Group Inc. Close Window