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    Auxiliary System Charge Air & Exhaust System: Sterling and Wilson Co-Gen Solutions

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    Keshav Shrivastava KS
    The document discusses the exhaust gas system for power plants. It describes the key components of the system including stacks, silencers, boilers and rupture discs. It notes that the system removes exhaust gases from the plant, keeps noise and emissions below limits. Pressure drops and causes of corrosion in the system are also summarized. Explosion protection measures for gas engines like purge fans and properly sized rupture discs are highlighted. Insulation of stacks is recommended in certain conditions to protect against corrosion.

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    Auxiliary System Charge Air & Exhaust System: Sterling and Wilson Co-Gen Solutions

    Uploaded by

    Keshav Shrivastava KS
    77 views17 pages
    The document discusses the exhaust gas system for power plants. It describes the key components of the system including stacks, silencers, boilers and rupture discs. It notes that the system removes exhaust gases from the plant, keeps noise and emissions below limits. Pressure drops and causes of corrosion in the system are also summarized. Explosion protection measures for gas engines like purge fans and properly sized rupture discs are highlighted. Insulation of stacks is recommended in certain conditions to protect against corrosion.

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    Exhaust System

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    The document discusses the exhaust gas system for power plants. It describes the key components of the system including stacks, silencers, boilers and rupture discs. It notes that the system removes exhaust gases from the plant, keeps noise and emissions below limits. Pressure drops and causes of corrosion in the system are also summarized. Explosion protection measures for gas engines like purge fans and properly sized rupture discs are highlighted. Insulation of stacks is recommended in certain conditions to protect against corrosion.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    77 views17 pages

    Auxiliary System Charge Air & Exhaust System: Sterling and Wilson Co-Gen Solutions

    Uploaded by

    Keshav Shrivastava KS
    The document discusses the exhaust gas system for power plants. It describes the key components of the system including stacks, silencers, boilers and rupture discs. It notes that the system removes exhaust gases from the plant, keeps noise and emissions below limits. Pressure drops and causes of corrosion in the system are also summarized. Explosion protection measures for gas engines like purge fans and properly sized rupture discs are highlighted. Insulation of stacks is recommended in certain conditions to protect against corrosion.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 17

    Auxiliary System

    Charge Air & Exhaust System

    Sterling and Wilson Co-Gen Solutions


    Clean and green environment
    AKK_27/03/2015 1
    Exhaust gas systems

    • The main function of the external exhaust gas system is to:


    – Lead the exhaust gases out from the power plant
    – Keep the noise level below the specified values
    – Keep the emission level below the specified values

    AKK_27/03/2015 2
    Exhaust gas system
    In case of gas engines:

    Ventilation fans

    Stack

    Rupture discs

    Branch pipe

    Exhaust
    Gas Silencer

    Exhaust
    Gas Boiler

    AKK_27/03/2015 3
    Exhaust gas ducting

    • Duct sizes based on exhaust gas velocity


    – < 30 m/s if gas engine
    – < 35 m/s if liquid fuel engine

    • Total Pressure drop limit (CA + EG)


    – < 7000 Pa if gas engine
    – < 5000 Pa if liquid fuel engine (CRO/HFO/LFO-mode)

    AKK_27/03/2015 4
    Typical pressure drops of components

    • Filters:
    – Oil wetted filter + F5 dry filter: 650 Pa (used)
    – Jet-pulse filter: 700 Pa (dirty)
    – Dry filter F5-F8: 450 Pa (dirty)
    – Marine filters 800-1200 Pa (clean)

    • Silencers
    – CA silencer 600-800 Pa
    – EG silencer 250-700 Pa

    • Boilers: 1200 Pa (clean) (2400 Pa for Gas engines without emission equipment)

    • Emission cleaning equipment


    – SCR and FGD 1200 Pa (clean)

    AKK_27/03/2015 5
    Causes for corrosion

    • GAS plants: Water dew point (full heat recovery)


    • HFO palnts (contains sulphur):
    – Sulphur dew point normally around 140-170°C
    – Exhaust gas temperature gets lower due to
    • Heat recovery boiler
    • Cold ambient temperature
    • Heavy wind or rain
    • Frequent stops and start-ups
    Risk for going down to dew point
    temperature
    Formation of sulphuric acid

    AKK_27/03/2015 6
    Effects of sulphuric acid

    • Stack material Corten A


    • Sulphuric acid will corrode
    stack’s inner surface
    • Surface starts to peel off
    • Corrosion chips (even the size
    of a hand) will fly to the
    surroundings like maple
    leaves

    AKK_27/03/2015 7
    Corrosion of stack

    AKK_27/03/2015 8
    Insulation of stacks

    • No insulation of stack is needed in cases where the stack < 50m and the exhaust
    gas temperature > 250°C. Insulation is not needed in cases where the exhaust gas
    temperature is > 300°C. In all other cases the stack shall be insulated.
    • Stacks are insulated mainly in cold conditions
    • In cold, humid or very corrosive atmosphere the stack needs to be insulated
    • In case of full heat recovery stack should be insulated
    • Painting / metallizing peels off after sometime, thus cost of repainting at regular
    intervals is very high. Thus, it is advisable to insulate the stack with aluminum
    cladding

    • Material of construction for stack duct:


    – Corton steel
    – SA 516 gr 60/70
    – Boiler quality steel

    AKK_27/03/2015 9
    Insulation of stacks

    Insulation will protect the stack


    50 mm rockwool + aluminium
    cladding

    • Costs about 5000 INR/m2 (material, delivery, installation)


    • “Air insulation” with only cladding saves about 1500 INR/m2
    • Price for not insulating?
    – Insulating after complaints from unhappy customer
    – In worst case changing the stacks
    – Image? Reputation?
    AKK_27/03/2015 10
    Gas Engines: Explosion protection

    • If unburned gas enters exhaust gas system, critical concentration may be


    reached -> Risk for explosion
    • Possible reasons
    – No ignition in one or several cylinders
    – Too rich air fuel mixture
    – Too lean air fuel mixture
    – Incorrect timing

    AKK_27/03/2015 11
    Gas Engines: Explosion protection

    • Explosion venting is a secondary protection to


    protect people, equipment and environment
    • Rupture disc :
    – POSITIONS: Bends, SCR, boiler, silencer,
    straight pipe (at every 10 diameters)
    – Diameter the same as for exhaust pipe
    – Opening pressure 0.5 bar(g) = 1,5 bar(a)
    • Ventilation fan to be operated every engine
    stop
    – To flush possible unburned fuel gas from
    ducting and equipment
    – Operated for five minutes

    AKK_27/03/2015 12
    Rupture discs

    • Disc diameter size same as duct size (DN1200 biggest size)


    – Too small size means more intense explosion
    – Low mass to minimize inertia => reducing opening time
    => less intense explosion
    – Open vent, no flying missiles

    • Indoor installations there has to be an outlet duct to outside at same size as


    rupture disc (max 6 m high)
    • Outlet to be covered with noise and weather protection
    • If in basement or any other place where outlet duct to ambient is too long then
    flame arrestors needed
    • Maximum distance between two discs 10 x duct diameter
    • Exhaust gas ducting should always be designed with upwards slopes towards the
    stack to avoid gas pockets

    AKK_27/03/2015 13
    Rupture disc, picture

    AKK_27/03/2015 14
    Exhaust gas purge fan

    • For gas engines only


    • Power consumption is 4 kW
    • Connected to branch pipe
    • Every time when engine is stopped fan is running 10 minutes
    • Fan starts, after three seconds butterfly valve opens

    AKK_27/03/2015 15
    AKK_27/03/2015 16
    AKK 07/12/2011
    AKK_27/03/2015 17
    AKK 07/12/2011

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