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Mechanical Services

Heat-Recovery Steam Generators & Bypass Stacks

HRSGHeat-Recovery Steam Generators (HRSGs) are found in plants & facilities that use gas turbines, like chemical processing industries, or in Combined-Cycle power plants. HRSGs recover the heat from a hot gas stream produced by gas turbines, then turns that heat into steam. The steam can be used to generate electricity in order to create power or run a combined-cycle power plant. In the cogeneration mode, steam produced from the HRSG is mainly used for process applications, whereas in the combined-cycle mode, power is generated via a steam turbine generator.

Although found mostly in newer facilities, an HRSG can be retrofitted and installed into an existing plant to help lower output costs and reduce emissions. While HRSGs form the major part of a steam / exhaust system in a combined-cycle power plant, a bypass stack is another important component. A gas turbine bypass system is designed to divert the flue gases from the HRSG to a bypass stack with a silencer assembly to allow the plant to operate in simple cycle mode. This allows the HRSG to be inspected, repaired, or have maintenance performed while it is isolated completely from the gas turbine.

Using a bypass stack also allows for combined cycle operation during the day and simple cycle operation at night when power demand is lowest, providing a greater savings in operation cost and efficiency over the life of the power plant. The bypass stack and diverter system permits power to be generated by the gas turbine even when the steam turbine cycle is down for a scheduled or unscheduled shut down, keeping the plant functional and avoiding potential power outages.

Just as with any major power plant equipment, the Heat-Recovery Steam Generator and the bypass stack require regular maintenance. These components are subject to extremely high temperatures. Although these components work together to extend the lifecycle and efficiency of the plant, they must be in proper working order and in good condition to function at full capacity. In combined-cycle power facilities or in industrial cogeneration plants, the HRSG is an important component to the plant’s total, overall efficiency. Since the HRSG & bypass stack are large metal structures commonly exposed to wide temperature fluctuations & environmental concerns, the system needs proactive attention to ensure continued reliability.

The rope access experts at Industrial Access are prepared to inspect and maintain the HRSG and bypass stack for your facility. Regular maintenance plans or emergency repairs can be provided as a cost-effective option that reduces maintenance budgets and downtime. Speak with one of our industry professionals to discuss inspections, maintenance, repairs, or replacement for Heat-Recovery Steam Generators and bypass stacks.

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