Waste Heat Recovery Boiler

1.

MAKE

BHEL Trichy. Sr.No.5035,5036,5037,5038 Vertical, Forced circulation Dual pressure, Top supported

2.

Type

3.

Design Pressrue(bar) Drum Economiser CPH Heating Surface (sqm). HP LP & CPH

: HP 85 146 18 : 90387 49558 LP 12 24.5

4.

5.

Pressure Part Section. Width (mm) Length (mm)

: 8160 20200

OPERATING CONDITIONS GT Fuel

:
NATURAL GAS HSD

UNIT

100% MCR

PEAK

100% MCR

80% MCR

HP Steam flow HP Steam pressure HP steam temp. HP feed water temp. LP steam flow LP steam pressure at SHO LP Steam Temp. LP feed water temp. CPH water inlet temp.

t/hr bar(a) deg C Deg t/hr bar(a) deg C deg C deg. C

225.9 65.0 530.0 106.0 46.764 5.7 206.0 106.0 48.0

244.58 70.0 540.0 105.6 45.612 6.0 207.0 105.6 49.0

224.61 65.0 531.0 141.0 48.85 5.7 196.0 140.0 46.0

192.23 56.4 536.01 141.00 40.00 4.82 193.0 140.0 44.0

GT Fuel

NATURAL GAS

HSD

UNIT

100% MCR

PEAK

100% MCR

80% MCR

CPH water to Deaerator

deg.C

98.0

98.0

46.0

44.0

GT exhaust flow
HP FW flow to HP ECO LP FW flow to LP ECO HP spray water flow

t/hr
t/hr. t/hr. t/hr

1697.72
223.95 46.764 1.95

1700.00
239.54 45.612 5.04

1698.95
222.667 48.848 1.94

1440.72
192.233 40.000 0.00

SAFETY VALVES
Location Type MAKE/ Nos. Set Press Kg/cmSq(g)

1. 2. 3. 4. 5. 6.

HP Drum LP Drum HP Eco outlet LP Eco outlet HPSH Outlet CPH outlet

1748 WB 1811-NA3X-20 1916 Mt 1910 Dc 1758 Wd 1910 Hc

BHEL/2 BHEL/2 BHEL/1 BHEL/1 BHEL/1 BHEL/1

85.70,88.3 11.2,11.6 147.9 28.0 81.8 17.0

DETAIL OF HEATING SURFACE AREA

Sr.No. Section Surface Area
(Heating)

1. 2. 3. 4. 5. 1. 2. 3. 4.

HP Evaporator HP Superheater-1 HP Superheater-2 HP Eco-1 HP Eco-2 Total LP Evaporator LP Superheater (Plain unfinned) LP Eco Condensate preheater Total Total B A+B A

29004.5 Sq.M. 5800.9 Sq.M. 5800.9 Sq.M. 23677.1 Sq.M. 26104.0 Sq.M. 90387.4 Sq.M. 23203.6 Sq.M. 724.5 Sq.M. 5327.4 Sq.M. 20203.1 Sq.M. 49558.6 Sq.M. 139946.0 Sq.M.

OPERATING PARAMETERS WITH NATURAL GAS FIRING

Description

units

100%MCR

Peak

80%MCR

60%MCR

Steam

HP Steam flow LP Steam flow Water HP feed water flow To HP Eco LP feed water flow To LP Eco HP Spray water Flow CPH inlet water Flow CPH bypass water flow CPH recirculation water Flow CPH Coil water flow With recirculation &By pass CPH water to recirculation

t/hr t/hr

225.940 46.784

244.580 45.612

194.940 37.404

164.160 32.544

t/hr
t/hr t/hr t/hr t/hr t/hr t/hr t/hr

223.950
46.764 1.95 268.308 91.872 50.863 273.304 268.304

239.540
45.612 5.04 286.484 71.532 69.228 284.180 286.484

193.750
37.404 1.19 228.024 46.188 72.276 257.112 228.024

163.660
32.544 0.50 196.770 41.940 68.080 222.906 196.770

TEMPERATURE

Ambient temperature 27 oC
Description units 100%MCR Peak 80%MCR 60%MCR

STEAM HP Steam SH outlet Temperature HP steam temp. after DESH HP steam Temp. Before DESH HP Drum steam temp. LP Steam SH outlet Temperature LP Drum steam Temp.

deg.C deg.C deg.C deg.C deg.C deg.C

530.00 443.00 452.00 285.00 206.00 160.00

540.00 431.00 454.00 289.00 207.00 160.00

534.00 452.00 459.00 274.00 199.00 152.00

523.00 453.00 456.00 263.00 197.00 151.00

Description

units

100%MCR

Peak

80%MCR

60%MCR

Feed Water HP ECO inlet temp. HP ECO-outlet temp. HP ECO-outlet water Temperature deg.C deg.C 106.00 160.00 105.60 157.00 105.80 151.00 106.00 151.00

deg.C

283.00 106.00 158.00

286.00 105.00 160.00

273.00 105.00 151.00

263.00 106.00 151.00

LP ECO inlet water temp.deg.C LP ECO outlet CPH inlet water temp. (Before Recirculation) CPH water Temp. (After Recir. Max.) deg.C

deg.C

48.10

49.10

46.00

44.00

deg.C

65.00

65.00

65.00

65.00

CPH outlet water temp. (Before Bypass) deg.C CPH water temp. To deaerator deg.C

112.00 98.00

112.30 98.00

111.00 98.00

112.00 98.00

Description

units

100%MCR

Peak

80%MCR

60%MCR

GAS TEG temp. at HRSG Inlet terminal point HP SH-I outlet HP Evaporate outlet HP ECOII outlet LP Evaporate outlet CPH outlet Stack temperature

deg.C
deg.C deg.C deg.C deg.C deg.C deg.C

559.50
474.80 294.60 224.30 166.30 101.00 101.00

586.20
489.00 301.00 223.00 223.00 101.00 101.00

559.30
473.00 284.00 214.00 214.00 97.00 97.00

540.00
461.00 271.00 271.00 271.00 96.00 96.00

PRESSURE Ambient temperature 27 oC

Description

units

100%MCR

Peak

80%MCR

60%MCR

HP SYSTEM HP Steam SH outlet Pressure HP Drum pressure HP feed control station Inlet pressure HP economiser-I inlet Pressure HP SH spray water press. HP SH spray C.V. outlet Pressure

bar(a) bar(a) bar(a) bar(a) bar(a) bar(a)

65.00 68.00 101.00 104.00 103.00 67.50

70.73 74.30 103.40 103.70 103.20 73.40

56.40 58.70 104.30 106.50 106.30 58.40

47.30 49.00 107.70 109.20 109.20 48.70

PRESSURE Ambient temperature 27 oC

Description

units

100%MCR

Peak

80%MCR

60%MCR

LP SYSTEM LP steam SH outlet Pressure LP Drum pressure

bar(a) bar(a)

5.70 6.30

5.99 6.50

4.82 5.30

4.80 5.10

LP feed control station Inlet pressure

LP economiser inlet Pressure

bar(a)

14.00

14.10

17.45

18.80

bar(a)

14.50

14.60

17.70

19.00

DRAFT PRESSURE Ambient temperature 27 oC

Description

units

100%MCR

Peak

80%MCR

60%MCR

GAS GT exhaust duct at Boiler Terminal point HPSH -I inlet draft CPH outlet draft Boiler outlet mbar 21.60 22.10 16.20 12.00

mbar mbar mbar

20.90 2.90 .50

21.30 15.60 .55

15.60 15.60 .40

11.0 1.55 .30

OPERATING PARAMETER WITH HSD FIRING Temperature

Ambient Temperature 27 degree

Description

units

100%MCR

80%MCR

Steam HP Steam SHO Temp. HP Steam Temp. After DESH HP Steam Temp. Before DESH HP Drum Steam Temp. LP Steam SHO Temp. LP Drum Steam Temp. Feed Water deg.C deg.C deg.C deg.C deg.C deg.C 531.00 444.00 454.00 285.00 196.00 160.00 536.50 461.00 461.00 274.00 193.00 152.00

HP ECO inlet Temp. HP ECO-I Outlet Temp. HP ECO-II Outlet Temp. LP ECO Inlet Temp. LP ECO outlet Temp. CPH Water Temp. to Deaerstor

deg.C deg.C deg.C deg.C deg.C deg.C

141.00 159.00 283.00 140.00 154.00 46.00

141.00 154.00 273.00 140.00 154.00 44.00

OPERATING PARAMETER WITH HSD FIRING Temperature

Ambient Temperature 27 degree

Description

units

100%MCR

80%MCR

GAS TEG Temp. at HRSG inlet HP SH-I outlet HP Evaporator Outlet HP ECO-II outlet LP Evaporator Outlet CPH Outlet deg.C deg.C deg.C deg.C deg.C deg.C 561.00 475.00 294.00 223.00 162.00 150.00 561.00 475.00 282.00 214.00 156.00 150.00

Stack Temperature

deg.C

150.00

150.00

PRESSURE Ambient Temperature 27 degree

Description

units

100%MCR

80%MCR

HP System
HP Steam SHO pressure HP Drum pressure HP Feed Control Station Inlet pressure HP ECO-I inlet pressure HP SH Spray water Inlet pres. HP SH Spray C.V Outlet Pres. HP Boiler Circulation Pump DP LP System LP Steam SHO Pressure bar(a) LP Drum Pressure bar(a) LP Feed Control Station Inlet pressure bar(a) LP ECO inlet Pressure bar(a) LP Boiler Circulation Pump DP bar(a) 5.70 6.30 14.00 14.50 1.55 4.82 5.30 17.45 17.70 1.55 bar(a) bar(a) bar(a) bar(a) Bar(a) Bar(a) bar(a) 65.00 68.00 101.00 104.00 103.50 67.50 2.90 56.40 58.70 104.30 106.50 106.30 58.40 2.90

DRAFT PRESSURE Ambient Temperature 27 degree

Description

units

100%MCR

80%MCR

GAS GT Exhaust Ductat Boiler Terminal Point HP SH-II inlet Draft Boiler Outlet mbar mbar mbar mbar 23.00 22.60 3.30 0.60 16.30 16.00 2.40 0.4

HP SUPERHEATER (I & II)

Description

unit

HP SH-I

HP SH-II

Tube OD Thickness Tube Type Tube material ST SL Arrangement No. of tubes wide No. of tubes high Fins Data No. of fins/meter Fin height Fin Thickness Fin Material

mm mm

31.8 3.2 SA 213 T-22 80 70

31.8 4.5 Spiral Finned 70 70

mm mm

Staggered
98 4 98 4

mm

150 15 1.3 A176 Type 409 A176

150 15 1.3 Type 409

Headers: Inlet header Size OD Thickness Material

unit

HPSH-I

HPSH-II

mm mm

219.1 32 SA 335 P 12

219.1 32 SA 335 P12

Outer header Size

OD Thickness Material

mm mm

219.1 32 SA 335 P 12

219.1 45 SA 335 P22

HP Evoporator : Tube OD Thickness Bend thickness Tube type Tube Material ST SL Arrangement No. of tubes wide No. of tubes high Fins Data No. of fins/meter Fin height Fin thickness Fin Material 150 15 1.3 St4 Din 1624 mm mm mm 31.8 2.9 3.2 Spiral finnel Sa210 Gr A1 80 70 Staggered 98 20

mm mm

mm mm mm

Evap. Links/Pipes :

Nos Description OD MM

Size Thickness MM

Material

Piping from Drum to Circ. Pump HP Boiler circulating pump Discharge pipe HP Boiler Circulating pump Discharge mainfold Mainfold to Evaporator inlet Links HP Evaporator to drum riser Inlet links

2 2

404.4 404.6

20 20

SA 106 GrB SA 106 GrB

1
8 16

406.4
127.0 127.0

25
8 8

SA 106 GrB
SA 106 GrB SA 106 GrB

HP Economiser-II
Tube OD Thickness Bendthickness Tube Type Tube material ST SL Arrangement No. of tubes wide No. of tubes high Fins Data No, of fins meter Fin height Fin thickness Fin material Headers : Size Thickness Material OD mm mm Inlet 219.1 22.2 SA 106 GrB Outlet 219.1 22.2 SA 106 GrB mm mm mm 31.8 2.9 3.2 Spiral finned SA 210 Gr A1 80 70 Straggered 98 18 150 15 13 ST4 DIN 1624

mm mm

mm mm

LP Superheater : (Unfinned tubes)

Tube OD Thickness Bend thickness Tube type Tube material ST SL Arrangement No. of Tubes wide No of tubes high Headers: No off OD mm Thickness Material Inlet One 219.1 8.8 SA 106 GrB Outlet One 219.1 8.8 SA 106 GrB mm mm mm 31.8 2.6 3.2 Plain tube SA 210 Gr A1 80 70 Inline 98 4

mm mm

mm

LP Evaporator : Tube OD Thickness Ben thickness Tube material ST SL Arrangement No of tubes wide No of Tubes high Fins Data : No of fins/ meter Fin height Fin thickness Fin material Headers : Inlet No off OD mm Thickness Material One 219.1 14.2 SA 106 GrB Outlet One 219.1 14.2 SA 106 GrB 150 15 13 St 4 DIN 1624 mm mm mm mm mm 31.8 2.6 3.2 SA 210 Gr A1 80 70 Staggered 98 16

mm mm

HP ECO-1

LP ECO

Tube OD Thickness Bend thickness Tube type Tube material ST SL Arrangement No of tubes wide No of tubes high

mm mm mm

31.8 2.9 3.2

mm mm

80 70 82 20

31.8 2.9 3.2 Spiral finned SA 210 Gr. A1 80 70 Staggered 16 20

Fins Data

:
HP ECO-1 LP ECO

No of fins/ meter Fin height Fin thickness Fin Material

mm mm

150 15 13 ST4 DIN 1624

150 15 13 ST4 DIN 1624

12).

CONDENSATE PRE- HEATER Tube OD Thickness Bend thickness Tube type Tube material ST SL Arrangement No. of Tube Wide No. of tube High Fins Data No of Fins/Meter Fin. Height Fin. Thickness Fin. Material Headers : Inlet Outlet No. off OD(mm) Thickness(mm) Material One 273 11 SA 106 Gr.BSA 106 Gr.B One 273 11 150 15 1.3 ST4 DIN 1624 mm mm mm 31.8 2.6 3.2 Spiral Finned SA 210 Gr.B 80 70 Staggered 98 14

mm mm

mm mm

HP/LP Drum

No. off

HP One

LP One

Inner diameter Thickness Material Internals

mm mm

2400 90 SA 299 Screen type driers

2300 22 SA 515 Gr.B