ProcessBarron designs, manufactures, and installs isolation doors to protect Heat Recovery Steam Generation (HRSG) systems. These HRSG systems are commonly found in coke plants, power plants, desalination plants, and universities. They are used to recover heat from hot gas streams, thereby generating steam for cogeneration or exclusive electrical generation.
The Origin and Design Challenge of HRSG Isolation Doors
Our initial isolation door design came about when ProcessBarron was contacted by an engineering group from North Carolina with a challenging request: to manufacture a custom guillotine or slide gate damper that could isolate an HRSG in the event of a failure. Initially, we declined the client’s bid request due to the high temperatures involved (2200 deg F).
However, when they requested that we design an alternative, we developed and proposed an HRSG isolation door concept. The undertaking involved a creative approach to liner systems, a novel business model, and a deep understanding of the supply chain.
Constructed from raw materials that can withstand high temperatures, the isolation door comprises a short section of duct. The HRSG system features a hinged door on the duct’s top portion, which can seal off the system’s hot side when rotated downward. When an HRSG failure is signaled, the door’s opening and closing mechanism is activated within 7 to 8 seconds by an alarm. This quick closing action allows hot gases to vent into the atmosphere, preventing further damage to the failed unit.
Another of the main reasons that this design has been successful is that all exposed metal components of the door assembly (including shafts, bearings, and supports) are outside of the air stream, protecting them from high temperatures.
The door is made with special materials. It has a heat-reflective coating. This prevents it from warping when it closes. The door is also exposed to hot gasses from a malfunctioning HRSG unit.
The door’s internal refractory components and innovative seals, developed by Bob Palmer of Empire Solutions, have proven effective in withstanding these extreme temperatures. Bob’s contribution to this project has demonstrated the collaborative business model that led to the creation of these HRSG isolation doors.
Applications of HRSG Isolation Doors
HRSG isolation doors protect equipment from high temperatures during emergencies or maintenance. For instance, the ProcessBarron business model has allowed us to supply 12 large units to an energy company in Ohio, with projections to supply several more to their plant in Granite City.
Some of the units have already been actuated during HRSG failures and successfully prevented further damage. We also have supplied three smaller units to an engineering company in Kentucky for a pellet mill operation.
The application of HRSG Isolation Doors goes beyond the specific scenario for which they were originally designed. This product can protect equipment from high temperatures in emergencies, system failures, or maintenance programs. It can be used in various situations in any facility.
While our equipment is typically installed in negative pressure systems, we can add special design features to accommodate some positive pressure solutions. We offer both electric and pneumatic drives, depending on the customer’s preference and the speed required for the door to cycle.
All of the refractory seal elements are replaceable during routine outages. We also offer routine inspection and maintenance of both the mechanical components and refractory elements.
HRSG systems typically fail due to flow accelerated corrosion, corrosion fatigue, and stress corrosion. If you suspect your system is vulnerable to these issues, please contact ProcessBarron. Our HRSG isolation doors provide a critical safeguard, reducing the risk of catastrophic failure and extending the lifespan of your HRSG system.
Impact on Supply Chain Management
It’s commonly known that ongoing supply chain disruptions are causing industrial manufacturers to reconsider their sources of raw materials. Recently, the industry has faced rising labor and shipping expenses, changing currency rates, and the goal of reaching sustainability targets.
In the case of ProcessBarron’s HRSG systems, the quality of our isolation doors is a testament to our supply chain efficiency used for production.
As explored above, the effectiveness of the Isolation Door lies in its unique design, representing a transformative business model in the field of industrial manufacturing, coupled with our supply chain efficiency, deep understanding of liner systems, and knowledge about what raw materials can endure high temperatures.
Our liner systems are made from materials that can handle high heat. Our liners can handle high heat. It is important to take care of them. Using the right design features will ensure they last a long time and work well. Therefore, enhancing the sourcing process for suitable raw materials plays a pivotal role in the innovative design and functionality of our HRSG isolation doors.
Another way we are enhancing the efficiency of our supply chain? The quick closing mechanism represents a significant evolution in manufacturing; by safeguarding the components of the failed unit from destruction, these doors signify a major advancement in heat recovery steam generation.
For more information on ProcessBarron’s work with HRSG isolation doors or HRSG Access Doors, and how we can incorporate HRSG isolation doors into your industrial manufacturing, whether it is a new or existing facility, contact us today. Our team is ready to provide the industrial manufacturing solutions that you need!