CCGT Power Plant – HRSG Side Wall Penetration Seal Retrofit in Spain

Originally built as a baseload power station, Cartagena’s operating equipment is not designed for high cycling. DEKOMTE proposed a bolted collar fabric expansion joint solution, that integrates to the HRSG cold casing and maintains a high cyclic capability, gas sealing penetration seal.

Client: Cartagena CCGT Power Plant

The Cartagena combined cycle thermal power station is a combined cycle thermoelectric station located in the Port of Escombreras, in the municipality of Cartagena, Spain. It consists of 3 thermal groups with a combined capacity of 1200 MW. It’s annual production is estimated at about 9,000 GWh, 3.5% of the total production of the peninsula.

Total Output:

1200 MW

Date Operational: 2006
Location: Cartagena, Spain
Primary Fuel: Natural Gas

Original: Metallic Bellow Side Wall Hot Reheat Outlet

Originally built as a baseload power station, Cartagena’s operating equipment is not designed for high cycling.

Regular problems caused by this design:
  • Limited cycling capability and flexibility for movements, which in turn leads to cracking, distortion and gas leakage.
  • Continual welding and repairs made for successful and safe operation.

Solution: DEKOMTE Penetration Seal Retrofit

DEKOMTE proposed a bolted collar fabric expansion joint solution, that integrates to the HRSG cold casing and maintains a high cyclic capability, gas sealing penetration seal. The original metallic bellow was overheating, causing deformations.

The new DEKOMTE fabric penetration seal solves the temperature consequences and installing carbon steel casing rings keeps the fabric away from the HRSG walls, allowing more freedom of movement. The installation of bolted casing and pipe collars allows the simplification of maintenance for future fabric replacement of the joint. The inner insulation bolsters are completely formed and designed for the HRH outlet, to give temperature protection to the joint and allow the movements to take place without being compressed.

 

Operating Temperature:

649°C

Static Pressure: 70 mbar
Movement: Axial: -10mm
Lateral: 169mm
Bellows removed, leaving pipe connection.
Bolted collars welded in place.
Internal collar insulation installed.
Pre-insulation installed.
Closing of gas-tight expansion joint.
Final installation.
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