Design optimization of compact gas turbine and steam combined cycles for combined heat and power production in a FPSO system–A case study

Abstract

This case study aims to cover a wide range of relevant aspects related to combined cycle design, mechanical integrity and operational reliability for cogeneration of heat and power in FPSO systems. The methods consist of combined optimization of combined cycle thermodynamic design and geometry of steam generator; vibration analysis for flow induced vibrations; and thermal stress estimation of casings during cold start-stop scenarios. Challenges and opportunities for reliable water treatment systems are explored. The results show that small tubes, a compact tube bundle and a low condensation temperature reduces the once-trough steam generator (OTSG) weight. The vibrations numerical simulations in this work support the standard recommendations of using 35 times tube OD as upper limit for the unsupported tube length, which could be used as a reasonable design criterion. Thermal stresses analysis indicates that the design of beam arrangement, location, and stiffness of beams has a major impact on thermal stresses, and can be optimized to different plate thicknesses in order to avoid fatigue damage. Focus should be on reducing leaks of deaerator, steam turbine and condenser. It is recommended to add Na sensors after condenser and investigating the use of Electrodeionization (EDI) technology for make-up water production from seawater.