Heat Recovery Steam Generators

Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Heat Recovery Steam Generators
Boiler Performance & Proposals – FBC & HRSG

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
Steam out
HRSG
or
Flue Gas in WHRB Flue Gas out
Feed water in


behind Gas Turbines

Why HRSG ?

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

Efficiency Levels

Combined Cycle Application

Combined Cycle Plant

Popular Gas Turbines

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

Plant Configuration Options

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

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

1300 MW Plant Configuration
Fr9FA GT 3PR HRSG
STG
Fr9FA GT 3PR HRSG
Fr9FA GT 3PR HRSG
STG
Fr9FA GT 3PR HRSG

for
Gas Turbines upto 60 MWe

HRSGs behind Fr 5 GT
Pressure Parameters In operation

Customer Power Output No of units
Level t/h kg/cm
2
°C from
32.5 MW
PPCL, Karaikal 1 HP 48.3 45.5 390 1999
1GT+1HRSG+1ST

HRSGs behind Fr 6 GT
Level t/h kg/cm
2
°C from
98 MW HP 59.3 62 483
AECO, Vatwa 2 1990
2GTs+2HRSGs+1ST LP 10.8 5 SAT
146 MW HP 58.4 62 483
GIPCL, Baroda 3 1990
97 MW HP 59.5 62 483
APSEB, Vijjeswaram 2 1990
2GTs+2HRSGs+1ST LP 11 5 SAT
146 MW HP 57.5 62 483
GEB, Utran 3 1991
103 MW
NEEPCO, Kathalguri 2 HP 59.7 41 473 1994
2GTs+2HRSGs+1ST
109 MW HP 60.1 80 520
RVUNL, Ramgarh 2 2003
2GTs+2HRSGs+1ST LP 15.4 6 200

for
Higher Capacity Gas Turbines
(60 – 160 MWe)

Triple Pressure HRSGs behind Fr 6FA GTs

Level t/h kg/cm
2
°C from
107.88 MW HP 110.6 107 537

TNEB, Kovilkalappal 1 IP 9.6 30 260 2001
1GT+1HRSG+1ST
LP 8.1 6 200
105 MW HP 105.4 107 537
TNEB, Perungulam 1 IP 8.6 30 260 2003
1GT+1HRSG+1ST
LP 7 6 200
100 MW HP 113.1 107 537
GSECL, Dhuvaran 1 IP 8.7 30 260 2003
1GT+1HRSG+1ST
LP 7.5 6 200
100 MW HP 110.7 107 542
TNEB, Kuttalam 1 IP 8.2 27.5 317 2004
1GT+1HRSG+1ST
LP 8.2 4.87 227
107 MW HP 118.2 107 542
GSECL, Dhuvaran Under
1 IP 8.3 30 260
Phase-II 1GT+1HRSG+1ST Execution
LP 6.6 6 200

HRSGs behind Fr 6FA GTs (70.14 MW ISO)

Tamilnadu
Customer Tamil Nadu
Electricity
Electricity Board
Board
HP IP LP
Parameters
Steam flow t/h 110.6 9.6 8.1
Pressure kg/cm2(a) 107 30 6.0
Temperature °C 537 260 200
GT Fuels NG
Commissioning February 2001
Salient Features Top supported

Module ht 12.1m
1 No HRSG for 107 MW CCPP
Two width
at TNEB,Kovilkalappal,India.
94 Modules

HRSGs behind Fr 9E GT

Level t/h kg/cm
2
°C from
165 MW HP 176 80 520

GIPCL, Baroda 1 1998
1GT+1HRSG+1ST LP 45.6 6 200
350 MW HP 188.4 80 520
NTPC, Kayamkulam 2 1999
330 MW HP 180.2 76.6 520
DVB, Pragati 2 2003
2GTs+2HRSGs+1ST LP 37.1 5.8 200
330 MW HP 187.1 79.2 514 Under
RVUNL-Dholpur 2
2GTs+2HRSGs+1ST LP 39.8 6 200 Execution

HRSGs behind Fr 9E GTs (123.4 MW ISO)

Customer National
Thermal Power
Corp. Ltd
Parameters HP LP
Steam flow t/h 188.4 39.5
Pressure kg/cm2(a)
80 6.0
Temperature °C 520 200
GT Fuels Naptha/NG/HSD
Commissioning October 1999
Salient Features Top supported

Module ht 18.8m
CPH re-circulation
2 Nos HRSGs for 350MW CCPP
Two width
102 Modules at NTPC,Kayamkulam,India.
HRSGs behind V94.2 GT
No of Pressure Parameters In operation

Customer Power Output
units Level t/h kg/cm
2
°C from
817 MW HP 225.9 65.3 530

NTPC, Dadri 4 1992
4GTs+4HRSGs+2ST LP 46.7 4.8 200
200 MW HP 226.7 79 525
TEC, Trombay 1 1994
1GT+1HRSG+1ST LP 46.1 6 200
400 MW HP 231 80 530
NTPC, Faridabad 2 2000

Dual Pressure HRSG

behind V94.2 GT (157 MW ISO)
Customer Tata Electric
Company, Trombay
Parameters HP LP
Steam flow t/h 226.7 46.1
Pressure kg/cm2(a) 80 7.0
Temperature °C 525 200
GT Fuels NG/HSD/Naphtha
Commissioning October 1994
Salient Feaures Bottom

supported
HRSG for 200 MW CCPP
Module ht 16.3m
at TEC,Trombay,India.
Three width

for
Advanced Class Gas Turbines

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

Arrangement of Reheat System
Hot Reheat
HP IP LP
Cold Reheat
HP Main Steam IP Main Steam LP Main Steam
HP IP LP
Drum Drum Drum
H H H H H
P R P R P H P I I I P L L
C
S H S H S P E P P P E P P
P
H H H E C S E E C S E
H
II I V H V C H V
II IB IA II I

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
Reheater Arrangement
Cold RH
Hot RH Steam
Steam
IP Steam
HP
HP
Steam Drum

Steam Parameters
For Combined Cycle System, Optimum Steam Pressure and temperature

levels for Triple Pressure Reheat System are
• HP : 120-130 bar and 535-565°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

Co-generation Application

Fired Cogeneration Plant

With FD Fan Mode Option
Fuel
Steam to process
Air
Air GT Exhaust
Exhaust
FD Fan
Fresh Air
HRSG
Feed water
Fuel

Supplementary Fired HRSG

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

Duct Burner(Gas) Arrangement

Duct Burner(Oil) Arrangement

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

HRSGs behind Fr 5 GTs (26.3 MW ISO)
Indian Oil
Customer
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 2 Nos HRSGs
21 Modules
for IOCL, Barauni
HRSG behind Fr5 GT with FD Mode Option

Oil & Natural Gas
Customer
Corporation Ltd
Plant Gandhar
GT+SF FD
Parameters
Mode Mode
Steam flow, t/h 62 64.8

Pressure , kg/cm2(a) 46 46
Temperature, °C 443 443
GT Fuel NG
HRSG Fuel Fuel Gas

Single width
27 Modules HRSG With FD Fan Mode

Duct Fired HRSG behind Fr 6 GT (38.34 MW ISO)

Customer Reliance Industries Ltd
Steam Drum
Plant PG Hazira Jamnagar
Parameters
E
Steam flow, t/h 125 125 125 E
S D S V
Pressure , kg/cm2(a) 105 118 116 B C
H H A
Temperature, °C 500 512 510 GT P
O
GT Fuel NG/Naptha/HSD Exhaust
HRSG Fuel NG/Naptha / HSD / Kerosene
Commissioned in 1995 1996-99 1999 13 Nos HRSG for RIL-Patalganga/

Hazira / Jamnagar, India.
Two width
66 Modules
125 tph even at 20MW GT load
(~3 times unfired output)

Duct Fired HRSG behind Fr 6 GT (38.34 MW ISO)
Customer Indian Petrochemicals Ltd Steam Drum
Plant Gandhar
GT+SF Mode FD Mode
Parameters
Steam flow, t/h 100 100 DB SH EVAP ECO
Pressure , kg/cm2(a) 108 108 GT
Temperature, °C 513 513 Exhaust
GT Fuel Naptha/HSD
HRSG Fuel Naptha / HSD / LDO
FD Fan

Two width
56 Modules
MCR Steam Output Even in 1 No HRSG behind Fr 6 GT
FD Mode for IPCL-Gandhar
Duct burner for 90Mkcal/h

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

Single width
40 Modules
Integrated Power Plant, India.
Furnace Fired
HRSG

HRSGs Vs Conventional Boilers

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

HRSGs-Classification
Gas flow direction Horizontal Vertical
Circulation Natural Assisted / Forced Once -Through
Firing Unfired Duct Fired Furnace Fired
Pressure Levels Single Multiple
Reheater Reheat Non-Reheat
Construction Modular Coil Design
Width Single Double Triple

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

BHEL Experience - HRSGs & WHRBs
WHRB (Sponge Iron) - 9

Combined Cycle - 49
Cogeneration
Unfired - 7
Supplementary Fired - 56
Total - 121
ALST-Alsthome Atlantique, France MHI-Mitsubishi Heavy Industries, Japan

JBE-John Brown Engg, UK MES-Mitsui Engg & Shipbuilding, Japan

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

Modular Construction
Single Row Module
Two Row Module

Arrangement of Modules

Arrangement of HRSG
SH Evaporator Economiser
DESH

Natural Circulation HRSG

 Horizontal Gas Flow
 Vertical Tubes

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

Manufacturing Facilities
for
HRSG

Shop facilities

Shop facilities

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

Waste Heat Recovery Boiler

For Process Plants

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

BHEL’s WHRBs
Sl Contract
Customer Units Steam Parameters Fuel Heat Source Status
No Year
Pressur Temp
Flow (t/h)
e (ata) (°C)
Prakash Industries Ltd, Sponge Iron In Operation

1 1991 1 46.8 53 410 Unfired
Chamba., MP Kiln Exhaust since 1993
Prakash Industries Ltd, Sponge Iron In Operation

2 1994 1 46.8 53 410 Unfired
Chamba., MP Kiln Exhaust since 1996
Sunflag Iron & Steel Co.,

Bhandra, Nagpur Sponge Iron In Operation
3 1994 1 45.0 65 485 Unfired
Kiln Exhaust since 1998
Maharastra.
Bhushan Steel & Strips

Sponge Iron Under
4 Ltd, Meramandali, 2004 4 55.4 105 540 Unfired
Kiln Exhaust Execution
Orissa
Jindal Stainless Ltd, Ferro Chrome Under

5 2004 2 28.5 42 405 Unfired
Dubri Orissa Kiln Exhaust Execution

Typical General Arrangement of

WHRB System for Sponge Iron Plant

Arrangement of WHRB

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)

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

Design
&
Operational Aspects

HRSG Temperature Profile

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

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)

Pinch Point

Approach Point

Optimisation of Heat Transfer Sections Arrangement

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

GT Characteristics
GT output / exhaust parameters

depend on
 Ambient Temperature
 RH
 Site Elevation
 Back Pressure
 Inlet Air cooling System
 Injection
 Combustor Type
 IGV position

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

CPH / Deaerator System

LP Steam
ST
HRSG CPH
Condenser
GSC
HP BFP
To HP Eco
CEP
IP BFP
To IP Eco
LP BFP
To LP Eco

CPH with Recirculation System

for Protection of CPH against Dew Point Corrosion
To Deaerator
From Condenser

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

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

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

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

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
Improvements

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

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

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

Optimisation of HRSG Inlet transition duct

Preferential Flow Pattern in Uniform Flow Pattern in Straight
Straight Transition Duct Transition Duct with Distribution Grid
Streamlined Flow pattern

in Composite Angle Duct

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

Cold Flow Study of
Steam Flow Distribution in Modules

Results of Scaled down 3D Water flow model studies

1.3
Four pass -Bottom row
1.2
Four pass -Top row
1.1
VARIATION
0.9
0.8 Single pass - Bottom row
Single pass - Top row

0.7
0 5 10 TUBE No. 15 20 25
Effect of number / location of nozzles
on Steam Flow Distribution
Uniform velocity
Low velocity
region
High velocity
region

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

Adoption of single row module

Modules with single row tube will
eliminate additional bending stresses
due to offset tube to header welds

Site Feedback
…Strategy adopted at… has

considerably compressed the
erection time… Insulation of
casings done in site …

Operational Flexibility of BHEL HRSGs
 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

Thank You

Heat Recovery Steam Generators

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