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Figure 18. Direct evaporator tube bundle arrangement. 2.4 FMEA/HazOp Study Placing a heat exchanger operating with a flammable hydrocarbon working fluid directly in the hot exhaust gas stream presents potential safety risks. To mitigate risks, FMEA and HazOp safety studies were performed. The most serious risks anticipated from heating the working fluid in direct proximity to a hot gas turbine exhaust were examined. Potential causes of tube breaches that would initiate a leak include thermal fatigue, mechanical vibration, corrosion, and manufacturing defects. 2.4.1 Thermal Fatigue Following a cold start of the direct evaporator, metal temperatures increase over a range of hundreds of degrees Celsius. Differential thermal expansion in the various materials used in the construction of the evaporator can put large stresses on the material interfaces, especially on welded joints between the working fluid tubes and the frame. Over the life of the evaporator unit, repeated cycles of startup and shutdown can eventually aggravate small imperfections in the weld to open cracks through which working fluid under high-pressure escapes from the tube into the hot TEG. A large leak would be noticed immediately from the measurable loss of working fluid, while the smallest leak could persist for weeks or months before it is recognized and repaired. 2.4.2 Mechanical Vibration The boiling process within the tubes, as well as the aerodynamic buffeting experienced by the tube banks during steady-state exhaust flow, contribute to vibration that can eventually fatigue and weaken the tube joints. Excessive strain of fatigued members could potentially open cracks in the tube material or welded joints, allowing a release of working fluid into the hot exhaust flow. These phenomena must be addressed during the design of the direct evaporator. 2.4.3 Corrosion Although substantially depleted of oxygen, the residual oxygen content, as well as the water content, of the exhaust flow from the gas turbine have a non-negligible potential to corrode the carbon steel of the direct evaporator fluid tubes over time. The risk of corrosion is already significantly reduced by observing a minimum exhaust temperature to prevent so-called “acid gas” exhaust components from precipitating 18PDF Image | Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
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