Bharat Heavy Electricals Limited TIRUCHIRAPALLI Boiler Performance & Proposals – FBC & HRSG Heat Recovery Steam Generators Heat Recovery Steam Generators
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Heat Recovery Steam GeneratorsHeat Recovery Steam Generators
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
What is HRSG / WHRB ?What is HRSG / WHRB ?
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
Flue Gas out
Steam out
Feed water in
HRSG or
WHRBFlue Gas in
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Heat Recovery Steam GeneratorsHeat Recovery Steam Generators behind Gas Turbinesbehind Gas Turbines
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Why HRSG ?Why HRSG ?
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSG ApplicationsHRSG Applications
HRSGs are used in:
Combined Cycle Power Plants to provide steam
to a steam turbine
Cogeneration Plants to provide steam for
industrial processes
Combined Cycle Cogeneration Plants to provide
steam to a steam turbine and the extraction
from steam turbine is used for industrial
processes
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Efficiency LevelsEfficiency Levels
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Combined Cycle ApplicationCombined Cycle Application
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Combined Cycle PlantCombined Cycle Plant
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Popular Gas TurbinesPopular Gas Turbines
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
No of HRSGs supplied to No of HRSGs supplied to Combined cycle plants by BHELCombined cycle plants by BHEL
Gas Turbines
GE Fr5 GE Fr6 GE Fr6FAGE Fr
9EV94.2 Others
2 14 5 7 7# 14 *
Total 49
•WH/W191(3 Nos); MES/SB30(1 No) ; MHI Fr 6 (4 Nos); ALST PG6541B(6 Nos)#4 HRSGs of Wagner Biro Design
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Plant Configuration OptionsPlant Configuration Options
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
100 MW Plant Configuration Options100 MW Plant Configuration Options
Fr6 GT 2P HRSG
STG
Fr6 GT 2P HRSG
Fr6FA GT 3P HRSG STG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
350 MW Plant Configuration Options350 MW Plant Configuration Options
Fr9E GT 2P HRSG
STG
Fr9E GT 2P HRSG
Fr9FA GT 3PR HRSG STG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
1300 MW Plant Configuration1300 MW Plant Configuration
Fr9FA GT 3PR HRSG
STG
Fr9FA GT 3PR HRSG
Fr9FA GT 3PR HRSG
STG
Fr9FA GT 3PR HRSG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Heat Recovery Steam Generators Heat Recovery Steam Generators
forfor
Gas Turbines upto 60 MWeGas Turbines upto 60 MWe
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs behind Fr 5 GT HRSGs behind Fr 5 GT
Parameters
t/h kg/cm2 °C
32.5 MW
1GT+1HRSG+1ST
In operation from
19991 HP 48.3 45.5 390PPCL, Karaikal
Pressure Level
Power OutputCustomer No of units
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs behind Fr 6 GT HRSGs behind Fr 6 GT Parameters
t/h kg/cm2 °C
98 MW HP 59.3 62 483
2GTs+2HRSGs+1ST LP 10.8 5 SAT
146 MW HP 58.4 62 483
3GTs+3HRSGs+3ST LP 12.4 5 SAT
97 MW HP 59.5 62 483
2GTs+2HRSGs+1ST LP 11 5 SAT
146 MW HP 57.5 62 483
3GTs+3HRSGs+3ST LP 11.5 5 SAT
103 MW
2GTs+2HRSGs+1ST
109 MW HP 60.1 80 520
2GTs+2HRSGs+1ST LP 15.4 6 200
In operation from
1990
1990
2
3
AECO, Vatwa
Pressure Level
2
Power OutputCustomer No of units
GIPCL, Baroda
APSEB, Vijjeswaram
GEB, Utran
NEEPCO, Kathalguri
RVUNL, Ramgarh
2 HP 59.7
1990
3 1991
2 2003
199441 473
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Heat Recovery Steam Generators Heat Recovery Steam Generators
for for
Higher Capacity Gas Turbines Higher Capacity Gas Turbines
(60 – 160 MWe)(60 – 160 MWe)
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Triple Pressure HRSGs behind Fr 6FA GTsParameters
t/h kg/cm2 °C
107.88 MW HP 110.6 107 537
IP 9.6 30 260
LP 8.1 6 200
105 MW HP 105.4 107 537
IP 8.6 30 260
LP 7 6 200
100 MW HP 113.1 107 537
IP 8.7 30 260
LP 7.5 6 200
100 MW HP 110.7 107 542
IP 8.2 27.5 317
LP 8.2 4.87 227
107 MW HP 118.2 107 542
IP 8.3 30 260
LP 6.6 6 200
1GT+1HRSG+1ST
1GT+1HRSG+1ST
Customer No of unitsPressure
LevelIn operation
fromPower Output
TNEB, Kovilkalappal 1 2001
TNEB, Perungulam 1 2003
1GT+1HRSG+1ST
1GT+1HRSG+1ST
GSECL, Dhuvaran Phase-II
1Under
Execution
GSECL, Dhuvaran 1 2003
TNEB, Kuttalam 1 2004
1GT+1HRSG+1ST
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs behind Fr 6FA GTs HRSGs behind Fr 6FA GTs (70.14 MW ISO)(70.14 MW ISO)
1 No HRSG for 107 MW CCPP
at TNEB,Kovilkalappal,India.
Tamilnadu
Electricity
Board
Customer
LP
GT Fuels NG
Commissioning February 2001
Parameters
Steam flow t/h
Pressure kg/cm2(a)
Temperature °C
HP
110.6
200
107
8.1
537
6.0
Salient Features Top supported
Module ht 12.1m
Two width
94 Modules
IP
9.6
30
260
Tamil Nadu Electricity Board
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs behind Fr 9E GTHRSGs behind Fr 9E GT
Parameters
t/h kg/cm2 °C
165 MW HP 176 80 520
1GT+1HRSG+1ST LP 45.6 6 200
350 MW HP 188.4 80 520
2GTs+2HRSGs+1ST LP 39.8 6 200
330 MW HP 180.2 76.6 520
2GTs+2HRSGs+1ST LP 37.1 5.8 200
330 MW HP 187.1 79.2 514
2GTs+2HRSGs+1ST LP 39.8 6 200
Power Output
RVUNL-Dholpur 2Under
Execution
Customer No of unitsIn operation
from
GIPCL, Baroda
Pressure Level
NTPC, Kayamkulam
DVB, Pragati
1998
1999
2003
1
2
2
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Salient Features Top supported
Module ht 18.8m
CPH re-circulation
Two width
102 Modules
Customer National
Thermal Power
Corp. Ltd
Commissioning
Parameters
Steam flow t/h
Pressure kg/cm2(a)
Temperature °C
HP
39.5
80 6.0
LP
Naptha/NG/HSD
October 1999
520
HRSGs behind Fr 9E GTs HRSGs behind Fr 9E GTs (123.4 MW ISO)(123.4 MW ISO)
2 Nos HRSGs for 350MW CCPP
at NTPC,Kayamkulam,India.
GT Fuels
188.4
200
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs behind V94.2 GTHRSGs behind V94.2 GT
Parameters
t/h kg/cm2 °C
817 MW HP 225.9 65.3 530
4GTs+4HRSGs+2ST LP 46.7 4.8 200
200 MW HP 226.7 79 525
1GT+1HRSG+1ST LP 46.1 6 200
400 MW HP 231 80 530
2GTs+2HRSGs+1ST LP 46.3 5 200
CustomerNo of units
Pressure Level
In operation from
Power Output
NTPC, Faridabad 2 2000
NTPC, Dadri 4 1992
TEC, Trombay 1 1994
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
226.7 46.1
80
Tata Electric
Company, Trombay
Parameters
Steam flow t/h
Pressure kg/cm2(a)
Temperature °C
Commissioning October 1994
7.0
525
Salient Feaures Bottom supported
Module ht 16.3m
Three width
HRSG for 200 MW CCPP at TEC,Trombay,India.
Customer
LP
GT Fuels NG/HSD/Naphtha
HP
200
Dual Pressure HRSG Dual Pressure HRSG behind V94.2 GT behind V94.2 GT (157 MW ISO)(157 MW ISO)
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Heat Recovery Steam Generators Heat Recovery Steam Generators
forfor
Advanced Class Gas TurbinesAdvanced Class Gas Turbines
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Triple Pressure Reheat HRSGTriple Pressure Reheat HRSG
• For maximum heat recovery from GT exhaust & better Combined
Cycle Heat Rate
• HP Steam to ST
• IP Steam to CRH or GT Injection ; HRH Steam to ST
• LP Steam to Deaerator / ST
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Arrangement of Reheat SystemArrangement of Reheat System
HP IP LP
HP Drum
HPSH
II
RH
II
HPSH
IB
RH
I
HPSH
IA
HPEV
HPEC
II
IP Drum
IPEV
IPEC
LP Drum
LPSH
LPEV
IPSH
HPEC
I
CPH
HP Main Steam
Cold Reheat
Hot Reheat
IP Main Steam LP Main Steam
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Reheat SystemReheat System
Ideally Suited for Advanced Class GTs due to the high level of GT exhaust flow and temperature
FeaturesFeatures
• Identical steam temperature for both HP Superheater / Reheater
• Sandwiching of Superheater and Reheater sections
• Optimum steam side pressure drop
• Cascaded Bypass system for Reheater for
• Normal Start up / Shut down
• Upset conditions like rapid load rejection and unit trip
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Reheater ArrangementReheater Arrangement
HP Drum
IP SteamHP Stea
m
Hot RH
Steam
Cold RH
Steam
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Steam ParametersSteam Parameters
For Combined Cycle System, Optimum Steam Pressure and
temperature levels for Triple Pressure Reheat System are
• HP : 120-130 bar and 535-565°C
• RH : 28-30 bar and 535-565°C
• LP : 4-7 bar and 200-230 °C
• Steam Flow rates for three Pressure levels are decided based on
optimum pinch and approach temperatures
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Co-generation Application Co-generation Application
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Fired Cogeneration PlantFired Cogeneration PlantWith FD Fan Mode OptionWith FD Fan Mode Option
Fuel
HRSGExhaust
Ste
am t
o p
roce
ss
AirG
T
Exh
aust
Fee
d
wat
er
FD FanA
irF
uel
Fresh Air
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Supplementary Fired HRSGSupplementary Fired HRSG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Natural gas
Naphtha
HSD
Kerosene
Light Diesel Oil
Intermediate Fuel Oil (Residual Oil)
Other distillate fuel oils ( LSHS etc )
Fuels For Supplementary FiringFuels For Supplementary Firing
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Duct Burner(Gas) ArrangementDuct Burner(Gas) Arrangement
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Duct Burner(Oil) ArrangementDuct Burner(Oil) Arrangement
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
No of HRSGs supplied to No of HRSGs supplied to Industrial customers by BHELIndustrial customers by BHEL
GE Fr3 GE Fr5 GE Fr6 Other GTs
Unfired Fired Unfired Fired Unfired Fired Unfired Fired
- 6 6 21 - 24 1* 5#
HRSGs behind Gas Turbines 63
HRSGs for other applications 9@
•ALST/MS 5001; # JBE/Fr5(2Nos); MES/SB60(3Nos) @ sponge iron plant
Upto HPCL-Visakh
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs behind Fr 5 GTs (26.3 MW HRSGs behind Fr 5 GTs (26.3 MW ISO)ISO)
2 Nos HRSGs
for IOCL, Barauni
Customer Indian Oil Corporation Ltd
Plant Barauni
Parameters Steam flow, t/h 48.2Pressure , kg/cm2(a) 40Temperature, °C 440GT Fuel Naptha/Gas/HSD HRSG Fuel Unfired
Commissioned in 2001
Salient Features Module ht 10.4m Single width 21 Modules
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSG With FD Fan Mode
HRSG behind Fr5 GT with FD Mode HRSG behind Fr5 GT with FD Mode OptionOption
Customer
Plant
Parameters GT+SF Mode
FD Mode
Steam flow, t/h 62 64.8
Pressure , kg/cm2(a) 46 46
Temperature, °C 443 443
GT Fuel
HRSG Fuel
Commissioned in
Salient Features
Oil & Natural Gas Corporation Ltd
Gandhar
NG
Fuel Gas
1997
Module ht 8.3m
Single width
27 Modules
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
13 Nos HRSG for RIL-Patalganga/ Hazira / Jamnagar, India.
Duct Fired HRSG behind Fr 6 GT Duct Fired HRSG behind Fr 6 GT (38.34 MW (38.34 MW ISO)ISO)
Steam Drum
GT Exhaust
ECO
EVAP
SH
DB
SH
Customer
Plant PG Hazira Jamnagar
Parameters Steam flow, t/h 125 125 125Pressure , kg/cm2(a) 105 118 116Temperature, °C 500 512 510GT FuelHRSG Fuel
Commissioned in 1995 1996-99 1999
Salient Features
(~3 times unfired output)
66 Modules
125 tph even at 20MW GT load
Reliance Industries Ltd
NG/Naptha/HSD NG/Naptha / HSD / Kerosene
Module ht 8.3m Two width
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Duct Fired HRSG behind Fr 6 GT Duct Fired HRSG behind Fr 6 GT (38.34 (38.34 MW ISO)MW ISO)
1 No HRSG behind Fr 6 GT for IPCL-Gandhar
GT Exhaust
ECOEVAPSH
Steam Drum
DB
FD Fan
Customer
PlantGT+SF Mode FD Mode
Parameters Steam flow, t/h 100 100Pressure , kg/cm2(a) 108 108Temperature, °C 513 513GT FuelHRSG Fuel
Commissioned in
Salient Features
56 Modules MCR Steam Output Even in FD Mode Duct burner for 90Mkcal/h
Indian Petrochemicals Ltd
Naptha/HSD Naptha / HSD / LDO
1997
Module ht 8.3m Two width
Gandhar
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
4 Nos HRSGs for IOCL-Panipat Integrated Power Plant, India.
MUHECOEVAPSH
Steam DrumMembrane Wall Water Cooled
Furnace
GT Exhaust
Furnace Fired HRSGs behind Fr 6 GTs Furnace Fired HRSGs behind Fr 6 GTs (39.62 MW (39.62 MW ISO)ISO)
Customer Indian Oil Corporation Ltd
Plant Panipat
Parameters Steam flow, t/h 110Pressure , kg/cm2(a) 48Temperature, °C 405GT Fuel Naptha/HSD HRSG Fuel IFO / HSD
Commissioned in 2001
Salient Features Module ht 12.1m Single width 40 Modules Furnace Fired HRSG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs Vs Conventional BoilersHRSGs Vs Conventional Boilers
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs Vs Conventional BoilersHRSGs Vs Conventional BoilersIn HRSGs 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 do not generally use membrane wall construction
Finned tubes used for compactness and maximum heat transfer
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs-ClassificationHRSGs-Classification
Firing Unfired Duct Fired Furnace Fired
Circulation Natural Assisted / Forced Once -Through
Gas flow direction Horizontal Vertical
Construction Modular Coil Design
Width
Pressure Levels Single Multiple
Single Double Triple
Reheater Reheat Non-Reheat
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
BHEL HRSGs - Road MapBHEL HRSGs - Road Map
1977 : First HRSG for Namrup, Assam - Based on In house Design
1982 : First Supplementary Fired HRSG for ONGC, Uran - In house design
1986 : First Furnace Fired, Dual Pressure HRSG with FD mode for ONGC-Hazira (Fr5 GT)
1988* : Technical Collaboration with
1989 : Auto Trip Transfer established within 1 minute at ONGC-Hazira
1991 : First Dual Pressure Triple width HRSG behind V94.2 GT for TEC-Trombay
1999 : First Triple Pressure HRSG behind Fr 6FA GT for TNEB-Kovilkalappal
2003 : First Furnace fired HRSG for firing Heavy Fuel Oil for IOCL-Panipat
* Extended upto 2010
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
ALST-Alsthome Atlantique, France
JBE-John Brown Engg, UK
MHI-Mitsubishi Heavy Industries, Japan
MES-Mitsui Engg & Shipbuilding, Japan
WHRB (Sponge Iron) - 9Combined Cycle - 49 CogenerationUnfired - 7 Supplementary Fired - 56
Total - 121
BHEL Experience - HRSGs & WHRBs BHEL Experience - HRSGs & WHRBs
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Features of BHEL HRSGsFeatures of BHEL HRSGs
Triple Pressure Reheat Natural circulation Horizontal configuration Modular construction Fully drainable sections Top Supported Complete internal insulation Composite Angle Inlet Transition duct Despatched as Loose Modules Insulation at Site
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Modular ConstructionModular Construction
Two Row Module
Single Row Module
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Arrangement of ModulesArrangement of Modules
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
DESH
SH Evaporator Economiser
Arrangement of HRSGArrangement of HRSG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Natural Circulation HRSGNatural Circulation HRSG
Horizontal Gas Flow
Vertical Tubes
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Internal InsulationInternal Insulation
Outer Duct Casing
Internal Insulation
Liner Plates
Flue Gas Path
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Manufacturing Facilities Manufacturing Facilities
for for
HRSGHRSG
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Shop facilitiesShop facilities
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Shop facilitiesShop facilities
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Facility created for larger size HRSG Module
Fabrication
Special facilitiesSpecial facilities
Module Height – Upto 26 m
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Waste Heat Recovery BoilerWaste Heat Recovery Boiler
For Process PlantsFor Process Plants
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Applications of WHRB
Recovering Heat in Industrial Exhausts from
Iron & Steel Plants
Copper / Zink Smelter Plants
Diesel Engines
Cement Plants
Chemical / Fertiliser Plants
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Sl No
Customer Contract
Year Units Steam Parameters Fuel Heat Source Status
Flow (t/h) Pressure (ata)
Temp (°C)
1 Prakash Industries Ltd, Chamba., MP
1991 1 46.8 53 410 Unfired Sponge Iron Kiln Exhaust
In Operation since 1993
2 Prakash Industries Ltd, Chamba., MP
1994 1 46.8 53 410 Unfired Sponge Iron Kiln Exhaust
In Operation since 1996
3
Sunflag Iron & Steel Co., Bhandra, Nagpur
Maharastra.
1994 1 45.0 65 485 Unfired Sponge Iron Kiln Exhaust
In Operation since 1998
4 Bhushan Steel & Strips Ltd, Meramandali, Orissa
2004 4 55.4 105 540 Unfired Sponge Iron Kiln Exhaust
Under Execution
5 Jindal Stainless Ltd, Dubri Orissa
2004 2 28.5 42 405 Unfired Ferro Chrome Kiln Exhaust
Under Execution
BHEL’s WHRBs
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Typical General Arrangement of WHRB System for Sponge Iron Plant
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Arrangement of WHRB
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Salient Features of BHEL WHRBs
Single Drum, Natural circulation & Top Supported design
Fully drainable heat transfer sections with Horizontal / Inclined
tubes
Two stage Superheater with interstage spray type attemperator
Non steaming Economiser
Economiser recirculation system
Induced Draft fan
Electrostatic Precipitator (ESP)
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Salient Features of BHEL WHRBs
Features for handling sticky dust laden (~ 65 g/Nm3) kiln exhaust gas
at high temperature (~1000°C)
Fusion / Fin welded membrane wall construction
Radiation chamber at inlet for reducing the gas temperature
Plain tube heat transfer sections
Inline Tube Arrangement
Inter-Bank Soot blowers for on-load cleaning
Cassette baffles to protect economiser coil bends from erosion
No convective sections in First pass & superheater, Evaporator
and economiser located in second/third passes
Single / Multipass vertical (Downward and Upward) gas flow
passes to enable positive dust settlement through hoppers
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Design Design
&&
Operational AspectsOperational Aspects
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Superheater
Evaporator
Economiser
Flue Gas
Pinch PointApproach Point
Te
mp
era
ture
HRSG Inlet HRSG Outlet
HRSG Temperature ProfileHRSG Temperature Profile
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Optimum Pinch & Approach Optimum Pinch & Approach TemperaturesTemperatures
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)
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Pinch Point Pinch Point
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Approach Point Approach Point
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Optimisation of Heat Transfer Sections Optimisation of Heat Transfer Sections Arrangement Arrangement
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Unique aspects in HRSG DesignUnique aspects in HRSG Design
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
Condensate / makeup water heating
Protection against water / acid condensation
Balancing the requirements at unfired / GT+SF / FD
modes
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
GT CharacteristicsGT Characteristics
GT output / exhaust
parameters depend on
Ambient Temperature
RH
Site Elevation
Back Pressure
Inlet Air cooling System
Injection
Combustor Type
IGV position
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Multiple Pressure Levels & Reheat Multiple Pressure Levels & Reheat SystemSystem
Single Pressure Non Reheat
% Efficiency : ~38-42
Dual Pressure Non Reheat
% Efficiency : ~42-50
Widely Used
Triple Pressure Non Reheat
% Efficiency : ~50-52
Triple Pressure Reheat
% Efficiency : 55-58 (Single RH) / 60 (Double
RH)
For Advanced Class Gas Turbines
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
CPH / Deaerator SystemCPH / Deaerator System
Condenser
ST
CPH
CEP
GSCHP BFP
IP BFP
LP BFP
To HP Eco
To IP Eco
To LP Eco
HRSG
LP Steam
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
CPH with Recirculation SystemCPH with Recirculation Systemfor Protection of CPH against Dew Point Corrosion
From Condenser
To Deaerator
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSG Start-up ConsiderationsHRSG Start-up Considerations
Temperature difference across thick walled components
Thermal stresses
Pressure stresses
Thermal stress plus pressure stress < Max. allowable
stress
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs for CCPP - Present TrendHRSGs for CCPP - Present Trend
Dual / triple pressure levels
Very high pressure
High superheat temperature
Low pinch Point
Close approach Temperature
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs for Co-gen Plants - Present HRSGs for Co-gen Plants - Present TrendTrend
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
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
HRSGs for Co-gen Plants - Present HRSGs for Co-gen Plants - Present TrendTrend
MCR steam output even at GT Part load
Introduction of SF at low GT loads
MCR steam output even in forced draft fan mode
Auto Trip Transfer
Non steaming economiser for a wide operating range
CPH to meet plant condensate requirements
Heavy Fuel Oil / Blended Fuel Oil Firing
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Future TrendsFuture Trends Advanced Class GTs - 200 MW and above
Reheat Cycle
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
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
ImprovementsImprovements
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Continuous Design ImprovementsContinuous Design Improvements
• In-house Developments & Analyses
• Joint Work with Educational Institutions (IIT)
• Seminars and International Conference
• Operational feedback from more than 100 HRSGs
• Feed back from manufacturing & Erection groups
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
In-house Developments & In-house Developments & AnalysesAnalyses
• Scaled down model Study done In-house for
• Gas flow distribution in HRSGs
• Steam flow distribution in Superheater Modules
• CFD Modeling
• Design of Flow Distribution Grid
• Composite Angle Inlet Transition Ducting
• Steam Flow Distribution
• Increased No. of nozzles for better steam distribution in Superheater modules
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Scale Down Model for Analysis of Scale Down Model for Analysis of Gas Flow Distribution in HRSG Gas Flow Distribution in HRSG
DuctDuct
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Preferential Flow Pattern in Straight Transition Duct
Streamlined Flow pattern in Composite Angle Duct
Optimisation of HRSG Inlet transition Optimisation of HRSG Inlet transition ductduct
Uniform Flow Pattern in Straight Transition Duct with Distribution Grid
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Grid Plate Constructed with Flat StripsGrid Plate Constructed with Flat Strips
Horizontal Strips
Outer Duct Casing
Internal Insulation
SS Liner
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Cold Flow Study of Cold Flow Study of Steam Flow Distribution in ModulesSteam Flow Distribution in Modules
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Results of Scaled down 3D Water flow model studies
0.7
0.8
0.9
1
1.1
1.2
1.3
0 5 10 15 20 25TUBE No.
VA
RIA
TIO
N
Single pass - Top row
Single pass - Bottom row
Four pass -Top row
Four pass -Bottom row
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Effect of number / location of nozzles Effect of number / location of nozzles on Steam Flow Distributionon Steam Flow Distribution
Low velocity region
High velocity region
Uniform velocity
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Further Improvements implemented in Further Improvements implemented in current HRSGscurrent HRSGs
Adoption of Single row module
Adoption of smaller header for reduced thermal stress and fatigue
damage
Adoption of composite angle inlet transition duct and gas
distribution grid constructed of flat strips
Insulation of HRSG Casing done at site for reducing Erection Time
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Modules with single row tube will
eliminate additional bending stresses
due to offset tube to header welds
Adoption of single row Adoption of single row modulemodule
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Site Feedback Site Feedback
…Strategy adopted at… has considerably compressed the erection time… Insulation of casings done in site …
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Single row modules Better welding access & Ease of Manufacture
Smaller headers Reduced header diameter & thickness, Reduced stress levels
Increased number & proper location of inlet nozzles Uniform flow distribution/metal temperatures, reduced
differential expansion between tubes in a module
Flexible connecting piping Adequate flexibility in interconnecting piping to ensure
unrestricted expansion of heat transfer modules
Adequately sized drains & vents For quick draining/venting of all modules To minimise thermal shock in superheater
Operational Flexibility of BHEL HRSGsOperational Flexibility of BHEL HRSGs
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Boiler Performance & Proposals – FBC & HRSG
Thank You Thank You