Heat Recovery Steam Generators

Bharat Heavy Electricals Limited
TIRUCHIRAPALLI
Boiler Performance & Proposals FBC & HRSG

Heat Recovery Steam Generators
TIRUCHIRAPALLI

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
WHRB
Flue Gas in
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behind Gas Turbines
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Gas turbine based
Simple
Cycle
Combined
Cycle
Cogen
Combined
Cycle Cogen
Conventional
Boiler & STG

35-40 23-42 38 60 75 - 90 50 - 70

Why HRSG ?
TIRUCHIRAPALLI

HRSG 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
TIRUCHIRAPALLI

Efficiency Levels
Gas turbine based
Simple
Cycle
Combined
Cycle
Cogen
Combined
Cycle Cogen
Conventional
Boiler & STG

35-40 23-42 38 60 75 - 90 50 - 70

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Combined Cycle Application
TIRUCHIRAPALLI

Combined Cycle Plant
TIRUCHIRAPALLI

Popular Gas Turbines

Model Power
MW (ISO)

GE
G3142(J) Fr 3 10.45
PG5371(PA) Fr 5 26.3
PG6561(B) Fr 6 42.1
PG6101(FA) Fr 6FA 70.14
PG9171(E) Fr 9E 123.4
PG9351 (FA) Fr 9FA 255.6

Siemens
V94.2 V94.2 157
V94.2A V94.2A 190
V94.3A V94.3A 265

TIRUCHIRAPALLI

No of HRSGs supplied to
Combined cycle plants by BHEL
Gas Turbines
GE Fr5 GE Fr6 GE Fr6FA GE Fr 9E V94.2 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
TIRUCHIRAPALLI

MODEL GT Power (MW)
HRSG Output
(Approx.)
ST Power
(Approx.)
CCP Power
(Approx.)
ISO Site (~) TPH MW MW
G3142(J) Fr3 10.45 9 20 5 14
PG5371(PA) Fr5 26.3 20 40 10 30
PG6561(B) Fr6 42.1 33 58+14 22 55
PG6101(FA) Fr6FA 70.14 65 110+8+8 35 100
PG9171(E) Fr9E 123.4 105 185+35 60 165
V94.2 V94.2 157 140 230+45 80 220
PG9351(FA) Fr9FA 255.6 220 270+45+30 110 330
Plant Configuration Options
TIRUCHIRAPALLI

100 MW Plant Configuration Options
Fr6 GT 2P HRSG
STG
Fr6 GT 2P HRSG
Fr6FA GT 3P HRSG STG
TIRUCHIRAPALLI

350 MW Plant Configuration Options
Fr9E GT 2P HRSG
STG
Fr9E GT 2P HRSG
Fr9FA GT 3PR HRSG STG
TIRUCHIRAPALLI

1300 MW Plant Configuration
Fr9FA GT 3PR HRSG
STG
Fr9FA GT 3PR HRSG
Fr9FA GT 3PR HRSG
STG
Fr9FA GT 3PR HRSG
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for
Gas Turbines upto 60 MWe
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HRSGs behind Fr 5 GT
Parameters
t/h
kg/cm
2
C
32.5 MW
1GT+1HRSG+1ST
In operation
from
1999 1 HP 48.3 45.5 390 PPCL, Karaikal
Pressure
Level
Power Output Customer No of units
TIRUCHIRAPALLI

HRSGs behind Fr 6 GT
Parameters
t/h
kg/cm
2
C
98 MW HP 59.3 62 483
2GTs+2HRSGs+1ST LP 10.8 5 SAT
146 MW HP 58.4 62 483
97 MW HP 59.5 62 483
2GTs+2HRSGs+1ST LP 11 5 SAT
146 MW HP 57.5 62 483
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 Output Customer No of units
GIPCL, Baroda
APSEB, Vijjeswaram
GEB, Utran
NEEPCO, Kathalguri
RVUNL, Ramgarh
2 HP 59.7
1990
3 1991
2 2003
1994 41 473
TIRUCHIRAPALLI

for
Higher Capacity Gas Turbines
(60 160 MWe)
TIRUCHIRAPALLI

Triple Pressure HRSGs behind Fr 6FA GTs
Parameters
t/h
kg/cm
2
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 units
Pressure
Level
In operation
from
Power Output
TNEB, Kovilkalappal 1 2001
TNEB, Perungulam 1 2003
1GT+1HRSG+1ST
1GT+1HRSG+1ST
GSECL, Dhuvaran
Phase-II
1
Under
Execution
GSECL, Dhuvaran 1 2003
TNEB, Kuttalam 1 2004
1GT+1HRSG+1ST
TIRUCHIRAPALLI

HRSGs behind Fr 6FA GTs (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/cm
2
(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
TIRUCHIRAPALLI

HRSGs behind Fr 9E GT
Parameters
t/h
kg/cm
2
C
165 MW HP 176 80 520
1GT+1HRSG+1ST LP 45.6 6 200
350 MW HP 188.4 80 520
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
Power Output
RVUNL-Dholpur 2
Under
Execution
Customer No of units
In operation
from
GIPCL, Baroda
Pressure
Level
NTPC, Kayamkulam
DVB, Pragati
1998
1999
2003
1
2
2
TIRUCHIRAPALLI

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/cm
2
(a)
Temperature C
HP
39.5
80 6.0
LP
Naptha/NG/HSD
October 1999
520
HRSGs behind Fr 9E GTs (123.4 MW ISO)
2 Nos HRSGs for 350MW CCPP
at NTPC,Kayamkulam,India.
GT Fuels
188.4
200
TIRUCHIRAPALLI

HRSGs behind V94.2 GT
Parameters
t/h
kg/cm
2
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
Customer
No of
units
Pressure
Level
In operation
from
Power Output
NTPC, Faridabad 2 2000
NTPC, Dadri 4 1992
TEC, Trombay 1 1994
TIRUCHIRAPALLI

226.7 46.1
80
Tata Electric
Company, Trombay
Parameters
Steam flow t/h
Pressure kg/cm
2
(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
behind V94.2 GT (157 MW ISO)
TIRUCHIRAPALLI

for
Advanced Class Gas Turbines
TIRUCHIRAPALLI

Triple 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
TIRUCHIRAPALLI

Arrangement of Reheat System
HP IP LP
HP
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
IP
Drum
I
P
E
V
I
P
E
C
LP
Drum
L
P
S
H
L
P
E
V

I
P
S
H

H
P
E
C

I
C
P
H
HP Main Steam
Cold Reheat
Hot Reheat
IP Main Steam LP Main Steam
TIRUCHIRAPALLI

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
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
TIRUCHIRAPALLI

Reheater Arrangement
HP
Drum
IP Steam
HP
Stea
m
Hot RH
Steam
Cold RH
Steam
TIRUCHIRAPALLI

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
TIRUCHIRAPALLI

Co-generation Application
TIRUCHIRAPALLI

Fired Cogeneration Plant
With FD Fan Mode Option
Fuel
HRSG
Exhaust
Air
FD Fan
Fresh Air
TIRUCHIRAPALLI

Supplementary Fired HRSG
TIRUCHIRAPALLI

Natural gas
Naphtha
HSD
Kerosene
Light Diesel Oil
Intermediate Fuel Oil (Residual Oil)
Other distillate fuel oils ( LSHS etc )
Fuels For Supplementary Firing
TIRUCHIRAPALLI

Duct Burner(Gas) Arrangement
TIRUCHIRAPALLI

Duct Burner(Oil) Arrangement
TIRUCHIRAPALLI

No of HRSGs supplied to
Industrial 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

TIRUCHIRAPALLI

HRSGs behind Fr 5 GTs (26.3 MW ISO)
2 Nos HRSGs
for IOCL, Barauni

Customer
Indian Oil
Corporation Ltd
Plant Barauni
Parameters
Steam flow, t/h 48.2
Pressure , kg/cm2(a) 40
Temperature, C 440
GT Fuel Naptha/Gas/HSD
HRSG Fuel Unfired
Commissioned in 2001
Salient Features Module ht 10.4m
Single width
21 Modules
TIRUCHIRAPALLI

HRSG With FD Fan Mode
HRSG behind Fr5 GT with FD Mode Option
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
TIRUCHIRAPALLI

13 Nos HRSG for RIL-Patalganga/
Hazira / Jamnagar, India.
Duct Fired HRSG behind Fr 6 GT (38.34 MW ISO)
Steam Drum
GT
Exhaust
E
C
O
E
V
A
P
S
H
D
B
S
H
Customer
Plant PG Hazira Jamnagar
Parameters
Steam flow, t/h 125 125 125
Pressure , kg/cm2(a) 105 118 116
Temperature, C 500 512 510
GT Fuel
HRSG 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
TIRUCHIRAPALLI

Duct Fired HRSG behind Fr 6 GT (38.34 MW ISO)
1 No HRSG behind Fr 6 GT
for IPCL-Gandhar
GT
Exhaust
ECO EVAP SH
Steam Drum
DB
FD Fan
Customer
Plant
GT+SF Mode FD Mode
Parameters
Steam flow, t/h 100 100
Pressure , kg/cm2(a) 108 108
Temperature, C 513 513
GT Fuel
HRSG 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
TIRUCHIRAPALLI

4 Nos HRSGs for IOCL-Panipat
Integrated Power Plant, India.
MUH ECO EVAP SH
Steam Drum Membrane Wall
Water Cooled
Furnace
GT
Exhaust
Furnace Fired HRSGs behind Fr 6 GTs (39.62 MW ISO)
Customer
Indian Oil
Corporation Ltd
Plant Panipat
Parameters
Steam flow, t/h 110
Pressure , kg/cm2(a) 48
Temperature, C 405
GT Fuel Naptha/HSD
HRSG Fuel IFO / HSD
Commissioned in 2001
Salient Features Module ht 12.1m
Single width
40 Modules
Furnace Fired
HRSG
TIRUCHIRAPALLI

HRSGs Vs Conventional Boilers

HRSG
Conventional
Boilers
Gas/Steam Ratio 3.5-7.0 1.0-1.2
Gas Inlet Temp. C < 650 >1200

TIRUCHIRAPALLI

HRSGs Vs Conventional Boilers

In 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
TIRUCHIRAPALLI

HRSGs-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
TIRUCHIRAPALLI

BHEL 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
TIRUCHIRAPALLI

3
2
6
21
24
3
1
4
1
6
5
7
7
9
8
14
0 2 4 6 8 10 12 14 16 18 20 22 24 26
Westinghouse-W191
MES-SB30
MES-SB60
MHI-Fr6
JBE-Fr 5
ALST-MS5001
ALST-Fr 6
GE/BHEL-Fr 3
GE/BHEL-Fr 5
GE/BHEL-Fr 6
GE/BHEL-Fr 6FA
GE/BHEL Fr 9E
Siemens-V 94.2
Sponge Iron Kiln
Fired Unfired
ALST-Alsthome Atlantique, France
JBE-John Brown Engg, UK
MHI-Mitsubishi Heavy Industries, Japan
MES-Mitsui Engg & Shipbuilding, Japan
WHRB (Sponge Iron) - 9
Combined Cycle - 49
Cogeneration
Unfired - 7
Supplementary Fired - 56

Total - 121
BHEL Experience - HRSGs & WHRBs
TIRUCHIRAPALLI

Features 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
TIRUCHIRAPALLI

Modular Construction
Two Row Module
Single Row Module
TIRUCHIRAPALLI

Arrangement of Modules
TIRUCHIRAPALLI

DESH
SH
Evaporator
Economiser
Arrangement of HRSG
TIRUCHIRAPALLI

Natural Circulation HRSG
Horizontal Gas Flow
Vertical Tubes
TIRUCHIRAPALLI

Internal Insulation
Outer Duct Casing
Internal Insulation
Liner Plates
Flue Gas Path
TIRUCHIRAPALLI

Manufacturing Facilities
for
HRSG
TIRUCHIRAPALLI

Shop facilities
TIRUCHIRAPALLI

Shop facilities
TIRUCHIRAPALLI

Facility created
for larger size
HRSG Module
Fabrication
Special facilities
Module Height Upto 26 m
TIRUCHIRAPALLI

Waste Heat Recovery Boiler
For Process Plants
TIRUCHIRAPALLI

Applications of WHRB
Recovering Heat in Industrial Exhausts from
Iron & Steel Plants
Copper / Zink Smelter Plants
Diesel Engines
Cement Plants
Chemical / Fertiliser Plants
TIRUCHIRAPALLI

Sl
No
Customer
Contract
Year
Units Steam Parameters Fuel Heat Source Status
Flow (t/h)
Pressur
e (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

BHELs WHRBs
TIRUCHIRAPALLI

Typical General Arrangement of
WHRB System for Sponge Iron Plant
TIRUCHIRAPALLI

Arrangement of WHRB
TIRUCHIRAPALLI

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)
TIRUCHIRAPALLI

Salient Features of BHEL WHRBs
Features for handling sticky dust laden (~ 65 g/Nm3) kiln exhaust gas
at high temperature (~1000C)
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
TIRUCHIRAPALLI

Design
&
Operational Aspects
TIRUCHIRAPALLI

Superheater
Evaporator
Economiser
Flue Gas
Pinch Point
Approach Point
HRSG Inlet
HRSG Outlet
HRSG Temperature Profile
TIRUCHIRAPALLI

Optimum Pinch & Approach Temperatures
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)
TIRUCHIRAPALLI

Pinch Point
Pinch Point

Steam Quantity
Material
HRSG Cost

Pinch Point Values Adopted
Optimum : 5 - 10 .C
Normal : 8 - 10 .C
Low : < 8 .C

TIRUCHIRAPALLI

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

TIRUCHIRAPALLI

Optimisation of Heat Transfer Sections Arrangement
TIRUCHIRAPALLI

Unique 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

TIRUCHIRAPALLI

GT Characteristics
GT output / exhaust parameters
depend on
Ambient Temperature
RH
Site Elevation
Back Pressure
Inlet Air cooling System
Injection
Combustor Type
IGV position
TIRUCHIRAPALLI

Multiple Pressure Levels & Reheat System
Single Pressure Non Reheat
% Efficiency : ~38-42
Dual Pressure Non Reheat
Widely Used
Triple Pressure Non Reheat
Triple Pressure Reheat
% Efficiency : 55-58 (Single RH) / 60 (Double RH)
For Advanced Class Gas Turbines
TIRUCHIRAPALLI

CPH / Deaerator System
Condenser
ST
CPH
CEP
GSC
HP BFP
IP BFP
LP BFP
To HP Eco
To IP Eco
To LP Eco
HRSG
LP Steam
TIRUCHIRAPALLI

CPH with Recirculation System
for Protection of CPH against Dew Point Corrosion
From Condenser
To Deaerator
TIRUCHIRAPALLI

HRSG Start-up Considerations
Temperature difference across thick walled components
Thermal stresses
Pressure stresses
Thermal stress plus pressure stress < Max. allowable stress
TIRUCHIRAPALLI

HRSGs for CCPP - Present Trend
Dual / triple pressure levels
Very high pressure
High superheat temperature
Low pinch Point
Close approach Temperature
TIRUCHIRAPALLI

HRSGs for Co-gen Plants - Present Trend
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
TIRUCHIRAPALLI

HRSGs for Co-gen Plants - Present Trend
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
TIRUCHIRAPALLI

Future 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
TIRUCHIRAPALLI

Improvements
TIRUCHIRAPALLI

Continuous 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
TIRUCHIRAPALLI

In-house Developments & Analyses
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
TIRUCHIRAPALLI

Scale Down Model for Analysis of
Gas Flow Distribution in HRSG Duct
TIRUCHIRAPALLI

Preferential Flow Pattern in
Straight Transition Duct
Streamlined Flow pattern
in Composite Angle Duct
Optimisation of HRSG Inlet transition duct
Uniform Flow Pattern in Straight
Transition Duct with Distribution Grid
TIRUCHIRAPALLI

Grid Plate Constructed with Flat Strips
Horizontal Strips
Outer Duct Casing
Internal Insulation
SS Liner
TIRUCHIRAPALLI

Cold Flow Study of
Steam Flow Distribution in Modules
TIRUCHIRAPALLI

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 25
TUBE No.
V
A
R
I
A
T
I
O
N
Single pass - Top row
Single pass - Bottom row
Four pass -Top row
Four pass -Bottom row
TIRUCHIRAPALLI

Effect of number / location of nozzles
on Steam Flow Distribution
Low velocity
region
High velocity
region
Uniform velocity
TIRUCHIRAPALLI

Further Improvements implemented in current
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
TIRUCHIRAPALLI

Modules with single row tube will
eliminate additional bending stresses
due to offset tube to header welds
Adoption of single row module
TIRUCHIRAPALLI

Site Feedback
Strategy adopted at has
considerably compressed the
erection time Insulation of
casings done in site

TIRUCHIRAPALLI

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 HRSGs
TIRUCHIRAPALLI

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Heat Recovery Steam Generators

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