GE 9FA CCGT Power Plant – HRSG Inlet High Cycling Expansion Joint in Wales

The complex frame geometry at the heart of the solution gives low fatigue stress from the thermal transients caused during cycling.

Client: Connah’s Quay Power Plant

The Connah’s Quay power plant consists of four 330 MW modules. Each module has a GE Frame 9FA gas turbine, a Stein Industrie heat recovery steam generator (HRSG) and a GE steam turbine; in a single-shaft layout. In 1956, the power plant was coal-fired, but was demolished and rebuilt in 1993 as the gas-fired power plant it is today.

Total Output:

1420 MW

Date Operational: 1956
Location: Flintshire, Wales
Primary Fuel: Natural Gas

Original: Low Quality Expansion Joint

The original expansion joint did not fulfil the operating condition and was insufficient for base load operation.

Regular problems caused by this design:
  • Steel frame with high structural rigidity, low flexibility, led to cracks and distortion allowing gas leakage.
  • Insufficient external insulation, poorly integrated to the frame system, causing fabric to overheat.
  • Welding and fabric replacement costs were found to be substantial, when considering all aspects (scaffolding, insulation, etc).

Solution: DEKOMTE 3WA Fabric Expansion Joint

The DEKOMTE 3WA fabric expansion joint was selected to be capable of the high cycling requirements and the reliable operation during the remaining lifetime of the plant. DEKOMTE designed, manufactured and turnkey installed an integrated concept of frame, fabric, convectors and external insulation system. The complex frame geometry at the heart of the solution gives low fatigue stress from the thermal transients caused during cycling. The plant set a minimum life of 20 years for the duct and heat recovery steam generator (HRSG), with minimum of 6-10 year maintenance life on the fabric.

 

Dimensions: 7500mm x 7500mm
Gas Velocity: 75 m/s
Static Pressure: +42 mbar
Movement: Axial: -200mm
Lateral: 77 / 25mm
Inspection of duct condition.
Installation of steel parts.
Installation of bolster and fabric expansion joint.
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