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HRSG : Heat Recovery Steam Generator Recovers heat energy available in GT Exhaust and Generates Steam WHRB : Waste Heat Recovery Boiler Recovers heat energy available in the Waste Gases from various Processes
Steam out
Flue Gas in
HRSG or WHRB
Feed water in
Why HRSG ?
Conventional Boiler & STG 35-40 Simple Cycle 23-42 Gas turbine based Combined Cogen Cycle 38 60 75 - 90 Combined Cycle Cogen 50 - 70
HRSG Applications
HRSGs are used in:
Combined Cycle Cogeneration Plants to provide steam to a steam turbine and the extraction from steam turbine is used for industrial processes
Efficiency Levels
GE G3142(J) PG5371(PA) PG6561(B) PG6101(FA) PG9171(E) PG9351 (FA) Siemens V94.2 V94.2A V94.3A
Fr 3 Fr 5 Fr 6 Fr 6FA Fr 9E Fr 9FA
MODEL
GT Power (MW) ISO 10.45 26.3 42.1 70.14 123.4 157 255.6 Site (~) 9 20 33 65 105 140 220
Fr6 GT
2P HRSG
STG
Fr6 GT
2P HRSG
Fr6FA GT
3P HRSG
STG
Fr9E GT
2P HRSG
STG
Fr9E GT
2P HRSG
Fr9FA GT
3PR HRSG
STG
Fr9FA GT
3PR HRSG
STG
Fr9FA GT
3PR HRSG
Fr9FA GT
Fr9FA GT
3PR HRSG
HRSGs behind Fr 5 GT
Customer
Power Output
No of units
Pressure Level
In operation from
PPCL, Karaikal
32.5 MW 1GT+1HRSG+1ST
HP
48.3
45.5
390
1999
HRSGs behind Fr 6 GT
Customer Power Output No of units Pressure Level HP LP HP LP HP LP HP LP HP HP LP Parameters t/h 59.3 10.8 58.4 12.4 59.5 11 57.5 11.5 59.7 60.1 15.4 kg/cm2 62 5 62 5 62 5 62 5 41 80 6 C 483 SAT 483 SAT 483 SAT 483 SAT 473 520 200 In operation from
AECO, Vatwa GIPCL, Baroda APSEB, Vijjeswaram GEB, Utran NEEPCO, Kathalguri RVUNL, Ramgarh
98 MW 2GTs+2HRSGs+1ST 146 MW 3GTs+3HRSGs+3ST 97 MW 2GTs+2HRSGs+1ST 146 MW 3GTs+3HRSGs+3ST 103 MW 2GTs+2HRSGs+1ST 109 MW 2GTs+2HRSGs+1ST
2 3 2 3 2 2
C 537 260 200 537 260 200 537 260 200 542 317 227 542 260 200
In operation from
107.88 MW TNEB, Kovilkalappal 1GT+1HRSG+1ST 105 MW TNEB, Perungulam 1GT+1HRSG+1ST 100 MW GSECL, Dhuvaran 1GT+1HRSG+1ST 100 MW TNEB, Kuttalam 1GT+1HRSG+1ST 107 MW 1GT+1HRSG+1ST
2001
2003
2003
2004
Under Execution
IP
110.6
107 537 NG
9.6
30 260
Module ht 12.1m
Two width 94 Modules
HRSGs behind Fr 9E GT
Customer Power Output Pressure No of units Level HP LP HP LP HP LP HP LP Parameters t/h 176 45.6 188.4 39.8 180.2 37.1 187.1 39.8 kg/cm2 80 6 80 6 76.6 5.8 79.2 6 C 520 200 520 200 520 200 514 200 In operation from
1 2 2 2
HP 188.4 80 520
GT Fuels
Commissioning Salient Features
Naptha/NG/HSD October 1999 Top supported Module ht 18.8m CPH re-circulation Two width 102 Modules
Customer
Power Output
4 1 2
Three width
HP
IP
LP
HP Main Steam
HP Drum
IP Main Steam
LP Main Steam
IP Drum
LP Drum
H P S H II
R H II
H P S H IB
R H I
H P S H IA
H P E V
H P E C II
I P S H
I P E V
I P E C
H P E C I
L P S H
L P E V
C P H
Reheat System
Ideally Suited for Advanced Class GTs due to the high level of GT exhaust flow and temperature
Features
Identical steam temperature for both HP Superheater / Reheater Sandwiching of Superheater and Reheater sections
Reheater Arrangement
Hot RH Steam HP Stea m Cold RH Steam
IP Steam
HP Drum
Steam Parameters
For Combined Cycle System, Optimum Steam Pressure and
temperature levels for Triple Pressure Reheat System are HP : 120-130 bar and 535-565C RH : 28-30 bar and 535-565C LP : 4-7 bar and 200-230 C Steam Flow rates for three Pressure levels are decided based on optimum pinch and approach temperatures
Co-generation Application
Air
FD Fan
Fresh Air Exhaust
HRSG
Natural gas
Naphtha
HSD
Kerosene
Light Diesel Oil Intermediate Fuel Oil (Residual Oil) Other distillate fuel oils ( LSHS etc )
63
9@
JBE/Fr5(2Nos); MES/SB60(3Nos)
Customer Plant Parameters Steam flow, t/h Pressure , kg/cm2(a) Temperature, C GT Fuel HRSG Fuel Commissioned in Salient Features
48.2 40 440 Naptha/Gas/HSD Unfired 2001 Module ht 10.4m Single width 21 Modules
Steam Drum
125 125 125 105 118 116 500 512 510 NG/Naptha/HSD NG/Naptha / HSD / Kerosene 1995 1996-99 1999
GT Exhaust
S H
D B
S H
E V A P
E C O
Module ht 8.3m Two width 66 Modules 125 tph even at 20MW GT load (~3 times unfired output)
100 100 108 108 513 513 Naptha/HSD Naptha / HSD / LDO 1997 Module ht 8.3m Two width 56 Modules MCR Steam Output Even in FD Mode Duct burner for 90Mkcal/h
GT Exhaust FD Fan
Customer Plant Parameters Steam flow, t/h Pressure , kg/cm2(a) Temperature, C GT Fuel HRSG Fuel Commissioned in Salient Features
EVAP
ECO
MUH
GT Exhaust
< 650
>1200
GT exhaust is the main heat source - no need for a firing system(unless supplementary fired).
Positive pressure of GT exhaust provides draft no need for fans (except FD Mode)
Steam generation at multiple pressure levels Heat transfer is predominantly through convection
HRSGs-Classification
Gas flow direction Circulation Firing Pressure Levels Reheater
Horizontal Natural Unfired Single Reheat Modular Vertical Assisted / Forced Duct Fired Multiple Non-Reheat Coil Design Once -Through Furnace Fired
Construction
Width
Single
Double
Triple
Unfired
9
7 7 5 8 6 6 1 2 1 3 3 4 14 24 21
WHRB (Sponge Iron) Combined Cycle Cogeneration Unfired Supplementary Fired Total
9 49 7 56
- 121
14 16 18 20 22 24 26
10
12
Horizontal configuration
Modular construction Fully drainable sections
Top Supported
Complete internal insulation Composite Angle Inlet Transition duct
Modular Construction
Single Row Module
Arrangement of Modules
Arrangement of HRSG
SH
Evaporator
Economiser
DESH
Internal Insulation
Outer Duct Casing Internal Insulation Liner Plates
Shop facilities
Shop facilities
Special facilities
Applications of WHRB
BHELs WHRBs
Sl No
Customer
Contract Year
Units
Steam Parameters Flow (t/h) Pressur e (ata) 53 53 Temp (C) 410 410
Fuel
Heat Source
Status
1 2
Prakash Industries Ltd, Chamba., MP Prakash Industries Ltd, Chamba., MP Sunflag Iron & Steel Co., Bhandra, Nagpur Maharastra.
1991 1994
1 1
46.8 46.8
Unfired Unfired
Sponge Iron Kiln Exhaust Sponge Iron Kiln Exhaust Sponge Iron Kiln Exhaust
1994
45.0
65
485
Unfired
Bhushan Steel & Strips Ltd, Meramandali, Orissa Jindal Stainless Ltd, Dubri Orissa
2004
55.4
105
540
Unfired
2004
28.5
42
405
Unfired
Arrangement of WHRB
Design &
Operational Aspects
HRSG Inlet
HRSG Outlet
Higher Pinch Point Lower Steam Qty - Less Material - Cheaper HRSG Lower Pinch Point Higher Steam Qty - More Material - Costlier HRSG Optimum Pinch Point (5 To 10 Deg.C) Higher Approach Point Lower Steam Qty - Less Material - Cheaper HRSG Steaming At Part Loads - Less likely Lower Approach Point Higher Steam Qty - More Material - Costlier HRSG Steaming At Part Loads - More likely Optimum Approach Point (5 to 10 Deg.C)
Pinch Point
Pinch Point Steam Quantity Material HRSG Cost
Approach Point
Approach Temp Steam Quantity Material HRSG Cost Eco Steaming Possibility
Approach Temperature Values Adopted Optimum : 5 - 10C Normal : 8 - 10C Low : < 8 C
HRSG is a slave system No direct control over inputs More than one HRSG feeding a Single Steam Turbine (2-2-1) Multiple Pressure levels Sliding pressure operation
GT Characteristics
GT output / exhaust parameters depend on
Ambient Temperature RH Site Elevation Back Pressure Inlet Air cooling System Injection Combustor Type IGV position
Triple Pressure Reheat % Efficiency : 55-58 (Single RH) / 60 (Double RH) For Advanced Class Gas Turbines
ST
HRSG
CPH
Condenser
GSC CEP
To Deaerator
From Condenser
Pressure stresses
Thermal stress plus pressure stress < Max. allowable stress
Dual / triple pressure levels Very high pressure High superheat temperature Low pinch Point Close approach Temperature
Increased steam demand / High supplementary firing Higher steam pressure and temperature Duct burner located between heat transfer surfaces SH steam temperature over a wide operating range
Future Trends
Stringent Environmental Regulations Nox : < 25 ppm with gas firing < 65 ppm with Liquid fuels Design for Two-shift operation / Cycling
Auto Plant Startup / Auto Plant Regulation State - of - art C & I Two stage supplementary firing Supplementary firing in HRSGs behind large GTs
Improvements
Scale Down Model for Analysis of Gas Flow Distribution in HRSG Duct
SS Liner
1.2
1.1
VARIATION
0.9
0.8
Uniform velocity
Site Feedback
Strategy adopted at has considerably compressed the erection time Insulation of casings done in site
Better welding access & Ease of Manufacture Reduced header diameter & thickness, Reduced stress levels Uniform flow distribution/metal temperatures, reduced differential expansion between tubes in a module
Smaller headers
Adequate flexibility in interconnecting piping to ensure unrestricted expansion of heat transfer modules
Thank You
Boiler Performance & Proposals FBC & HRSG