GT26 CCGT Power Plant – HRSG Access Door in England

DEKOMTE proposed an internally lined access hatch, suitable for retrofitting to the existing ‘cold case’ exhaust system. The solution involved a new section of liner plate with aperture fixing to integrate with the existing liner plates, ensuring the insulation will be well maintained and protected from turbulence.

Client: Staythorpe Power Plant

Staythorpe is the second biggest combined cycle gas turbine power station in the UK, capable of generating electricity for over two million homes. It consists of four KA26-1 units, each with an Alstom GT26B gas turbine, a triple-pressure heat recovery steam generator (HRSG) and a steam turbine. Electricity is created using Alstom TOPGAS hydrogen-cooled generators.

Total Output:

1735 MW

Date Operational: 2011
Location: Nottinghamshire, England
Primary Fuel: Natural Gas

Original: Aged Access Door

The original door had sustained prolonged heat damage due to inefficient design.

Regular problems caused by this design:
  • The casing around the door is distorted and weakened by heat exposure.
  • The door frame is severely warped.
  • The insulation in adjacent casing area is missing due to turbulent flow around the liners.
  • Insulation in the door appears compacted.
  • Tightness of door to frame and the required gasket gives some leakage.

Solution: DEKOMTE Retrofit Access Hatch

DEKOMTE proposed an internally lined access hatch, suitable for retrofitting to the existing ‘cold case’ exhaust system. The solution involved a new section of liner plate with aperture fixing to integrate with the existing liner plates, ensuring the insulation will be well maintained and protected from turbulence.

The door and liner plate interface features a double sealing system to manage the temperature gradient to the outer frame. The outer frame brings the door away from the casing, protecting from any further heat exposure or adjacent insulation issues. The Davit arm support mechanism was chosen to avoid manual handling issues with the manoeuvring of the door during outages.

Existing door frame cut out.
Internal liner plate cut out.
New frame welded in and Davit arm installed.
Liner plated and insulation installed.
Fitting of the door.
Painted with heat resistant paint.
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