Steampower Systems

SPS Training,
Óscar Cubero,
Company Confidential May 2016 2
KELVION – STEAM POWER SYSTEMS
EXECUTIVE TRAINING
SPS Training,
Óscar Cubero,
TABLE OF CONTENTS
1. INTRODUCTION
2. STEAM POWER SYSTEMS
3. FWH
4. HRSG
5. RECUPERATORS
6. VSC
7. ACC
8. OTHER STEAM POWER EQUIPMENT
9. ROUTES TO MARKET
10. Q&A
SPS Training,
Óscar Cubero,
1.
INTRODUCTION
SPS Training,
Óscar Cubero,
May 2016 5
Company Confidential
CONTACT DATA
Manufacturing & Engineering
KELVION THERMAL SOLUTIONS, Global Sales Team
S.A.U. KELVION
SPAIN
Óscar Cubero Fernando Ruiz
CEO / S&T PES Product Line Manager Sales Director Steam Power Systems
oscar.cubero@kelvion.com fernando.ruiz@kelvion.com
+34.946.315.000 +34.946.315.000
_____________________________________
___________________
VSC
Antonio Moreno julen.artetxe@kelvion.com
Operations Director cesar.ramirez@kelvion.com
antonio.moreno@kelvion.com veronica.pardo@kelvion.com
+34.946.315.000 HRSG
___________________ isidro.montoya@kelvion.com
ivan.alechiguerra@kelvion.com
Manuel Laguna
FWH
Engineering Director
ivan.alechiguerra@kelvion.com
manuel.laguna@kelvion.com
cesar.ramirez@kelvion.com
+ 34.913.530.000
SPS Training,
Óscar Cubero,
May 2016 6
KELVION THERMAL SOLUTIONS, S.A.U.

• Kelvion Thermal Solutions, S.A.U. is a company based in Spain with three main
operations:
Barrio San Juan, 28 Polígono Trascueto, B-1 and D-1 Juan Ignacio Luca de Tena, 6
48140 Igorre (Bizkay) 39600 Revilla de Camargo 28027 Madrid
Spain Spain Spain
• Headquarters of the • Manufacturing site for S&T • Engineering office for AFC-
Kelvion Spanish products: ST products and S&T
operations. • Steam power systems products.
• Manufacturing place of • Miscelaneous HX • Thermal & Mechanical
AFC-ST products • Miscelaneous PV engineers.
(components & projects) • Two different halls: CS / SS • Process engineers
• 100 permanent employees • 80 permanent employees • Draftman.
• Production capacity up to • Production capacity up to • Commissioning engineers
200.000 h. 100.000 h.
SPS Training,
Óscar Cubero,
May 2016 7
KELVION THERMAL SOLUTIONS, S.A.U.

Broad product range for all applications and segments and Center of Competence of key products.
SPS Training,
Óscar Cubero,
2.
STEAM POWER SYSTEMS

SPS Training,
Óscar Cubero,
May 2016 9
POWER PLANT BASIC SCHEME
VSC
HRSG
ACC
FWH
SPS Training,
Óscar Cubero,
May 2016 10
PRODUCT RANGE (PER UNIT)

MW CHP BIOMASS THERMOSOLAR POWER PLANT COMBINED CYCLE PLANT CONV. FOSSIL / NUCLEAR PLANT
1.000
900
800
700
600
ST ST ST
500
400
300
200 GT GT GT
100 ST
ST
GT
GT GT
0 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
HRSG VSC ACC FWH MIS. HRSG VSC ACC FWH MIS. HRSG VSC ACC FWH MIS. HRSG VSC ACC FWH MIS. HRSG VSC ACC FWH MIS.
HRSG : from 1,0 M€ to 4 M€

VSC : from 0,2 M€ to 4 M€
Typical market prices: ACC : from 0,3 M€ to 4 M€
FWH : from 0,4 M€ to 1 M€
MIS.: from 0,3 M€ to 4 M€
SPS Training,
Óscar Cubero,
3.
FWH
SPS Training,
Óscar Cubero,
May 2016 12
PURPOSE AND BASIC TYPES

• Feed Water Heaters (FWH) are key power plant components. Their main purpose to
improve the thermodynamic efficiency of the Rankine steam cycle.
• They are used to heat the condensate and the boiler feed water before entering into the
boiler. Feed water temperature can be raised up to 200 ºC.
• The heating fluid is the steam comming from the different extractions of the HP, MP and
LP steam turbines.
• There are two basic type of FWH:

• Closed FWH: where the steam and the condensate / feedwater are not mixed up. This is
the kind of FWH we are going to describe in this section.
• Open FWH: where the steam and the condensate / feedwater are mixed. The most
common example is the deaerator.
• A closed feed-water heater is typically s shell and tube type heat exchanger where the
condensate / feed water passes through the tubes and it is heated by turbine extraction
steam that is feed by the shell side.
SPS Training,
Óscar Cubero,
May 2016 13
BASIC SCHEME
LP FWH:
Between condensate
STEAM pumps and main boiler
TURBINE feedwater pumps.
HP FWH:
Between main boiler
VSC feed water pumps and
BOILER
boiler.
MP FWH:
UP TO 4 DEAERATOR (uncommon)
UP TO 3
If there is a booster
HP HP LP pump between
FW FW FW
H H
deaerator and boiler
H
feedwater pumps, a MP
FWH can be also
installed
SPS Training,
Óscar Cubero,
May 2016 14
HP & LP FWH LP FWH:

• Condensate at the VSC hotwell is around 50 ºC. This
condensate, together with the water make-up, needs to be
deaerated before entering the boiler. Deaeration process
occurs at 105 ºC.
• The most efficient way of heating up the condensate is by
LP steam turbine extractions. On the contrary this LP steam
will be finally condensed at the VSC with very significant
heat losses.
HP FWH:
• Storage tank at the deaeration station, keeps the boiler feed
water at 105 ºC.
• Each 5,5 ºC of temperature increase at the boiler
economizer inlet, the boiler efficiency increases a 1%.
• The most efficient way of heating up the boiler feed water is
by MP and HP steam turbine extractions.
• Additionally a boiler feed water temperature above 140 ºC
will avoid sulphur corrosion due to acid dew point.
SPS Training,
Óscar Cubero,
May 2016 15
HP FWH
• HP FWH uses steam from the
HP steam turbine extraction
• At that point, steam is

superheated, that is why we
need to install a first section
called de-superheating zone.
• Then it comes the condensing

zone.
• Finally the subcooling zone
• Tube side operating pressure

moves from 100 bar to 300 bar
• Shell operating pressure moves

from 20 bar to 70 bar
SPS Training,
Óscar Cubero,
May 2016 16
LP FWH
• LP FWH uses steam from the
LP steam turbine extraction
• At that point, steam is saturated

or close to saturation, that is
why we don’t need to install a
de-superheating zone.
• First section is the condensing

zone.
• Final section is the subcooling

zone.
• Tubes side operating pressure

are from 10 bar to 20 bar
• Shell operating pressure are

normally < 10 bar
SPS Training,
Óscar Cubero,
May 2016 17
FLEXIBLE ARRANGEMENT
HORIZONTAL VERTICAL CHANNEL DOWN VERTICAL CHANNEL UP
• Most typical arrangement • Low space requirements • Low space requirements

• High plot needs • Disassembly only can be done • Disassembly only can be done
• Better flow control by removable shell. by removable bundle.
• Less condensate retention • Complex maintenance • Complex maintenance
time • Requires more surface for the • Subcooling area should cover
• Disassembly either by same performance. the full equiment lenght (water
removable shell or bundle • Highly influenced by seismic from bottom to top).
• Most of them are floor loads. • Requires more surface for the
mounted. • Only used in case of lack of same performance.
space. • Complex bundle drainage
• Less used arrangement.
SPS Training,
Óscar Cubero,
May 2016 18
TECHNICAL DATA
BUSINESS TYPE Component business
Basic and detailed engineering, purchasing, manufacturing, installation, supervision
SCOPE OF SUPPLY
on-site, commissioning and after sales services.
• HEI
Thermal design • HTRI
• In-house software
DESIGN CODES & STANDARDS • ASME VIII Division I
• ASME VIII Division II
Mechanical design
• AD-Mekblatter
• In-house software
Design pressure Up to 500 bar
Thickness Up to 3 mm
TUBES
LP FWH : CS / Alloyed Steel / Austenitic SS
Materials
HP FWH : CS / Alloyed Steel / Austenitic & Ferritic SS
Thickness Up to 600 mm
TUBESHEET
• Forging SA350LF2 / SA266Gr2
Materials
• Solid type / overlay with special or alloyed material.
SHELL Thickness Up to 30 mm
Materials Carbon steel
SPS Training,
Óscar Cubero,
May 2016 19
RELEVANT REFERENCE
MARKET SEGMENT POWER
SUBSEGMENT CENTRAL
APPLICATION COAL POWER PLANT
PRODUCT FWH
PLANT C.T. LADA
CUSTOMER IBERDROLA
END USER IBERDROLA
COUNTRY SPAIN
STEAM TURBINE
ELEC. OUTPUT (MW) 350
YEAR 2015
SPS Training,
Óscar Cubero,
4.
HRSG
SPS Training,
Óscar Cubero,
May 2016 21
GAS TURBINES
• Gas turbine, also called a combustion
turbine, is a type of internal combustion
engine.
• It has an upstream rotating air
compressor coupled by a shaft to a
downstream turbine, and a combustion
chamber in between.
Gas turbines are normally delivered to the market as complete packages including:
1.- Gas turbine

2.- Lube oil system
3.- Electrical Generator
4.- Mechanical coupling
5.- Air cooling and filtering system
X.- Control system, Gas fuel system
The exhaust gases after the downstream turbine section have a high temperature and enthalpy.
With a proper recovery system, it is possible to produce: steam, hot water or both together.
SPS Training,
Óscar Cubero,
May 2016 22
LAY-OUT A HRSG recovers the heat from the gas

turbine exhaust and produces steam.
It requires a deep knowledge on different

disciplines:
• Codes & standards

• Local regulations
• Industrial processes
• Heat transfer
• Thermodynamics
• Mechanical design
• Fluid mechanics: gases, water and steam
• Noise attenuation
• Metalurgy
• Heat insulation
• Environmental matters
• Fire management and protection systems
• Safety
• Electricity
• Instrumentation & Control
SPS Training,
Óscar Cubero,
May 2016 23
PARTS OF A HRSG
1 Expansion Joint
12
2 By-pass system
11 3 By-pass silencer
4 1
4 By-pass stack
10
5 Gas ducting
3 9
1 6 Additional firing / Burner

1
1 2 5 6
8
7 Superheater
7
8 Evaporation section / Boiler
9 Economizer
10 Additional heat recovery system
11 Exhaust gases stack
12 Emissions probes
SPS Training,
Óscar Cubero,
May 2016 24
HEAT TRANSFER SECTIONS: SUPERHEATER
Superheater section is delivered to

the field as a stand alone section,
with its own internally insulated
casing and supportive structure.
SPS Training,
Óscar Cubero,
May 2016 25
HEAT TRANSFER SECTIONS: EVAPORATOR

OR BOILER
Evaporation section is delivered to the field as a stand alone section, with its own internally
insulated casing and supportive structure.
SPS Training,
Óscar Cubero,
May 2016 26
HEAT TRANSFER SECTIONS:

ECONOMIZER
The economizer section is delivered to

the field as a stand alone module,
including inlet and outlet headers, heat
exchange surfaces and casing.
It is normally externally insulated at the

field.
SPS Training,
Óscar Cubero,
May 2016 27
HEAT TRANSFER SECTIONS:

HEAT EXCHANGE TUBES
BASE TUBE FINS
O.D. MATERIAL TYPE MATERIAL HEIGHT DENSITY
NONE - - -
A-335-P11
SUPERHEATER 2” AISI-409 3/4” 6 FINS/INCH
A-335-P22 SERRATED
AISI-421 3/4” 6 FINS/INCH
NONE - - -
EVAPORATOR 2” A-192 AISI-409 3/4” 6 FINS/INCH
SERRATED
C.S. 3/4” 6 FINS/INCH
ALUMINUM 3/5” 8 FINS/INCH
ECONOMIZER 1” A-192 SOLID
C.S. 3/5” 8 FINS/INCH
SPS Training,
Óscar Cubero,
May 2016 28
INSTRUMENTATION
SPS Training,
Óscar Cubero,
May 2016 29
CONTROL
Control cabinets &

Contro system
SPS Training,
Óscar Cubero,
May 2016 30
RELEVANT REFERENCE
SUBSEGMENT DECENTRAL
APPLICATION COGENERATION - CHP
PRODUCT HRSG
CUSTOMER FENICE
END USER TIOXIDE
COUNTRY ITALY
GAS TURBINE CX-400
STEAM 25 Tm/h
20 bar
300 ºC
YEAR 2013
SPS Training,
Óscar Cubero,
May 2016 31
RELEVANT REFERENCE
APPLICATION COGENERATION - CHP
PRODUCT HRSG
CUSTOMER IDAE
END USER TORRASPAPEL
COUNTRY ESPAÑA
GAS TURBINE TITAN T-250
STEAM 1 40 Tm/h
42 bar
420 ºC
STEAM 2 4 Tm/h
16 bar
Saturated
HOT WATER 3000 Kwt
YEAR 2010
SPS Training,
Óscar Cubero,
5.
RECUPERATORS
SPS Training,
Óscar Cubero,
May 2016 33
COMBUSTION ENGINES
• Internal combustion engine (ICE) is a heat engine where the combustion of a fuel occurs
with an oxidizer (usually air) in a combustion chamber that is an integral part of the working
fluid flow circuit. In an internal combustion engine the expansion of the high- temperature
and high-pressure gases produced by combustion apply direct force the crankshaft of the
engine.
• The exhaust gases at the engine exhaust section have a high temperature and enthalpy.
With a proper recovery system, it is possible to produce: hot water or thermal oil.
SPS Training,
Óscar Cubero,
May 2016 34
TYPICAL LAY-OUT
When only heat water or thermal oil heating is
needed, typically with combustion engines
applications, exhaust gases enthalpy is
recovered though very simple recuperators.
They normally consists in a traditional

shell & tube equipment, with a by-pass.
SPS Training,
Óscar Cubero,
May 2016 35
CONSTRUCTIVE DETAILS
Horizontal
Vertical
SPS Training,
Óscar Cubero,
6.
VACUUM SURFACE
CONDENSERS
SPS Training,
Óscar Cubero,
May 2016 37
KEY POWER PLANT COMPONENT
AIR COOLED CONDENSER VACUUM SURFACE CONDENSERS

SPS Training,
Óscar Cubero,
May 2016 38
MAIN DUTIES
CONDENSATE THE STEAM AND CREATE VACUUM REMOVE THE NON-CONDENSABLE GASES
• Vaccum is created by the process itself.
• For the start up and in operation in order to help to
mantain the vacuum as well as to extract the non-
condensable gases, a vacuum system is installed.
• There are two basic type of vacuum systems:
• Steam jet system
• Liquid ring pumps system
P1
STEAM GEN
TURBINE
Po
Po
SPS Training,
Óscar Cubero,
May 2016 39
WORKING SCHEME
Cooling water outlet
Non-condensables (O2,
N2,..)
Exhaust
& Steam
Water vapor
Cooling water inlet
Condensate
SPS Training,
Óscar Cubero,
May 2016 40
WORKING SCHEME
SMALL (CIRCULAR) LARGE (RECTANGULAR)
• Up to 100 Mw (aprox.)
• From 100 Mw (aprox.)
• Up to Ø 3200mm (aprox.)
• From Ø 3200mm (aprox.)
• Dome up to Ø 1800mm (aprox.)
Constructive features: Steam entry:

• Nr. of Passes: 1 or 2 • Vertical
• Divided or Non-divided water channels • Axial
• High degree of pre-assembly
SPS Training,
Óscar Cubero,
May 2016 41
SCOPE OF SUPPLY: COMPLETE SYSTEM

We supply the complete system :
 Main condenser
Axial duct Atmospheric  Expansion joint
relief
 Transition duct between steam turbine exhaust
Gland steam and condenser.
condenser
 Hotwell
Main
 Vacuum system (steam ejectors / liquid ring
condenser pumps)
Rupture
disk  Cleaning system
 Flash tank
Hotwell
 Drain header
 Safety devices (Relief valves, Rupture dics)
Condensate pumps Vacuum unit
 Condensate pumps
 Dump condenser
 Gland condenser
 Valves & Trim
 Local and remote instruments
SPS Training,
Óscar Cubero,
May 2016 42
P&ID
SPS Training,
Óscar Cubero,
May 2016 43
VACUUM SYSTEM OPTIONS : STEAM JET

SPS Training,
Óscar Cubero,
May 2016 44
VACUUM SYSTEM OPTIONS: LIQUID RING

PUMPS
SPS Training,
Óscar Cubero,
May 2016 45
PRE-ASSEMBLY POSSIBILITIES
SPS Training,
Óscar Cubero,
May 2016 46
RELEVANT REFERENCES
SUBSEGMENT CENTRAL
APPLICATION COMBINED CYCLE
PRODUCT VSC
PLANT LOS MINA C.C.
CUSTOMER TECNICAS REUNIDAS
END USER AES
COUNTRY DOMINICAN REPUBLIC
STEAM TURBINE
YEAR 2015
SPS Training,
Óscar Cubero,
May 2016 47
RELEVANT REFERENCES
APPLICATION THERMOSOLAR
TECHNOLOGY CSP - PARABOLIC

THROUGH
PRODUCT VSC
PLANT OUARZAZATE SOLAR

POWER STATION –
NOOR 1
CUSTOMER ACCIONA / SENER / TSK
END USER ACWA POWER
COUNTRY MOROCCO
STEAM TURBINE SIEMENS
YEAR 2014
SPS Training,
Óscar Cubero,
May 2016 48
RELEVANT REFERENCES
MARKET SEGMENT OIL & GAS
SUBSEGMENT UPSTREAM
APPLICATION FLNG
PRODUCT VSC
PLANT OPHIR’S GUINEA
CUSTOMER PETER BROTHERHOOD
END USER KEPPEL / GOLAR
COUNTRY EQUATORIAN GUINEA
STEAM TURBINE DRESSER RAND
ELEC. OUTPUT (MW)
YEAR 2014
SPS Training,
Óscar Cubero,
7.
AIR COOLED CONDENSERS

SPS Training,
Óscar Cubero,
May 2016 50
SMALL PLANTS
Dry condensing systems with no need of additional make up water.

Applications:
Coal Power plants
Combined Cycles
Co-generation (CHP) plants
Biomass plants
Industrial plants (paper mills)
Three (3) possible tube configurations:
A TUBE ALEX TUBE MASH TUBE

 Elliptical tube  Flat tube covered  Round core tube
by aluminum.
 Hot Deep  External sleeve of
Galvanized  Brazed welding. Aluminum tube.
 Suitable for  Light weight.  Extruded fins.
agressive
environments
SPS Training,
Óscar Cubero,
May 2016 51
RELEVANT REFERENCE
APPLICATION THERMOSOLAR
TECHNOLOGY FRESNEL
PRODUCT ACC
PLANT PUERTO ERRADO
CUSTOMER OHL
END USER TUBO SOL PE2
COUNTRY SPAIN
STEAM TURBINE THERMODYNE - GE
YEAR 2014
SPS Training,
Óscar Cubero,
8.
OTHER STEAM POWER

EQUIPMENT
SPS Training,
Óscar Cubero,
May 2016 53
STEAM STORAGE TANKS

2 x Steam storage
tanks for a
Thermo Solar
Power plant in
Spain
9 x Steam storage tanks

for a Thermo Solar
Power plant in France.
SPS Training,
Óscar Cubero,
May 2016 54
NUCLEAR MARKET SEGMENT POWER
SUBSEGMENT CENTRAL
APPLICATION NUCLEAR
TECHNOLOGY FISION NUCLEAR
PRODUCT COOLING HX
PLANT JHR
CUSTOMER ENSA / AREVA
END USER JHR
COUNTRY FRANCE
YEAR 2016
SPS Training,
Óscar Cubero,
May 2016 55
NUCLEAR
SUBSEGMENT CENTRAL
APPLICATION NUCLEAR
TECHNOLOGY FUSION NUCLEAR
PRODUCT TRITIUM WATER TANKS
PLANT ITER
CUSTOMER ENSA
END USER ITER
COUNTRY FRANCE
YEAR 2015
May 2016 56
9.
ROUTES TO MARKET
SPS Training,
Óscar Cubero,
May 2016 57
STEAM POWER SYSTEMS
OEM (Gas turbines packagers) New equipment

HRSG
EPC Contractors New equipment
End users Replacement
VSC OEM (Steam turbine manufacturers) New equipment
ACC OEM (Steam turbine manufacturers) New equipment
FWH
MISCELLANEA EPC Contractors New equipment
SPS Training,
Óscar Cubero,
10.
Q&A
Q&A’S
YOUR TURN
SPS Training,
Óscar Cubero, May 60
2016

Steampower Systems

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Steampower Systems

Încărcat de

Drepturi de autor:

Formate disponibile

SPS Training,

KELVION – STEAM POWER SYSTEMS

KELVION THERMAL SOLUTIONS, S.A.U.

KELVION THERMAL SOLUTIONS, S.A.U.

STEAM POWER SYSTEMS

POWER PLANT BASIC SCHEME

PRODUCT RANGE (PER UNIT)

HRSG : from 1,0 M€ to 4 M€

PURPOSE AND BASIC TYPES

• There are two basic type of FWH:

HP & LP FWH LP FWH:

• At that point, steam is

• Then it comes the condensing

• Finally the subcooling zone

• Tube side operating pressure

• Shell operating pressure moves

• At that point, steam is saturated

• First section is the condensing

• Final section is the subcooling

• Tubes side operating pressure

• Shell operating pressure are

• Most typical arrangement • Low space requirements • Low space requirements

APPLICATION COAL POWER PLANT

PLANT C.T. LADA

END USER IBERDROLA

ELEC. OUTPUT (MW) 350

1.- Gas turbine

LAY-OUT A HRSG recovers the heat from the gas

It requires a deep knowledge on different

• Codes & standards

1 6 Additional firing / Burner

HEAT TRANSFER SECTIONS: SUPERHEATER

Superheater section is delivered to

HEAT TRANSFER SECTIONS: EVAPORATOR

HEAT TRANSFER SECTIONS:

The economizer section is delivered to

It is normally externally insulated at the

HEAT TRANSFER SECTIONS:

O.D. MATERIAL TYPE MATERIAL HEIGHT DENSITY

Control cabinets &

APPLICATION COGENERATION - CHP

END USER TIOXIDE

GAS TURBINE CX-400

APPLICATION COGENERATION - CHP

END USER TORRASPAPEL

GAS TURBINE TITAN T-250

HOT WATER 3000 Kwt

They normally consists in a traditional

KEY POWER PLANT COMPONENT

AIR COOLED CONDENSER VACUUM SURFACE CONDENSERS

Cooling water inlet

Constructive features: Steam entry:

SCOPE OF SUPPLY: COMPLETE SYSTEM

VACUUM SYSTEM OPTIONS : STEAM JET

VACUUM SYSTEM OPTIONS: LIQUID RING

APPLICATION COMBINED CYCLE

PLANT LOS MINA C.C.

CUSTOMER TECNICAS REUNIDAS

END USER AES

COUNTRY DOMINICAN REPUBLIC

ELEC. OUTPUT (MW) 120

TECHNOLOGY CSP - PARABOLIC

PLANT OUARZAZATE SOLAR

CUSTOMER ACCIONA / SENER / TSK