HEAT RECOVERY STEAM

GENERATOR

BY
B. AJI
RONY JOHNSON
 Roadmap of the Presentation

• HRSG OVERVIEW

• HRSG CONSTRUCTIONAL &

STARTUP ASPECTS.

• SITE PROBLEMS FEED BACK

 COMBINED CYCLE PLANT HEAT
FLOW DIAGRAM
45.9 %

GT
STG
POWER(30%)
POWER(15.9%)

STACK LOSS(14%)
FUEL(100%) GAS TURBINE
EXHAUST CONDENSER
HEAT(67%) LOSS(34.3%)

MISC.LOSS(3%) MISC.LOSS(2.8%)
 BHEL IS MANUFACTURING HRSG’S

IN TECHNICAL COLLABORATION WITH VOGT USA

HORIZONTAL NATURAL CIRCULATION HRSG’S

HRSGS ARE MADE FOR COGENERATION CYCLES AND

COMBINED POWER CYCLES.

SINGLE OR MULTI PRESSURE HRSGS

FIRED & UNFIRED HRSGS

FEATURES FOR HIGHER COMBINED CYCLE EFFICIENY

LOW PINCH POINT

CLOSE APPROACH POINT

HIGH STEAM TEMPERATURES

USE OF REHEATERS
 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)
HRSG Temperature Profile
Temperature

Flue Gas
Superheater
Pinch Point
Approach Point
Evaporator
Economiser

HRSG Inlet HRSG Outlet

 HRSG ARRANGEMENT

GAS FLOW IS HORIZONTAL.

HP SUPERHEATERS

HP EVAPORATOR

ECONOMISER 2

LP SUPERHEATER

LP EVAPORATOR

ECONOMISER 1

CONDENSATE PREHEATER
 HEAT EXCHANGE SURFACES

HRSGS ARE PROVIDED WITH MORE HEAT TRANSFER

SURFACE IN A COMPACT MANNER.

BHEL HRSGS USE SEAMLESS STEEL TUBES .

THE FINS ARE ELECTRIC RESISTANCE WELDED BY HIGH

FREQUENCY TO ENSURE GOOD CONTACT WITH THE TUBE.
 Spiral Finned Tube
– Finned tubing used to increase heat transfer
– Two types - Solid fins and Serrated fins
– Serrated fins have higher heat transfer rate
STEAM DRUM,DUCTING & INTERNAL INSULATION

DRUM IS DESIGNED WITH CENTRIFUGAL SEPERATORS

AND FINAL SCRUBBERS TO PROVIDE HIGH PURITY STEAM
TO SUPERHEATER.

INLET DUCTING IS PROVIDED TO RECEIVE HOT GAS FROM

GAS TURBINE.
 Internal Insulation
Outer Duct Casing

Internal Insulation

Liner Plates

Flue Gas Path

 Stack Temperature

– Lower stack temperature - higher efficiency

– Lower stack temperature achieved by
• Introduction of CPH/MUH
• Steam generation at Dual /triple pressure levels

– Dictated by
• Acid dew point (for fuels with sulphur)
• Water dew point (for fuels without sulphur)
 Special Features of BHEL HRSGs
 Compact Design

 Use of High Frequency Welded High

Efficiency Spiral Finned Tubes

 Natural circulation Module Tube to Header

 Single / Multi pressure level

 Modular construction

 Fully drainable sections

 Complete internal insulation

CONTROLS

DRUM LEVEL CONTROL BY FEED FLOW MODULATION

SUPERHEATER TEMPERATURE CONTROL BY

DESH SPRAY WATER FLOW MODULATION.

CPH INLET & OUTLET WATER TEMERATURE CONTROL.

KAYAMKULAM MCR PARAMETERS

PARAMETER HP LP

STEAM FLOW 188.4 39.5

STEAM PR: 80 6

STEAM TEMP 520 200

FEED WATER TEMP 151.3 150.2

CPH FLOW 544.7

CPH I/L TEMP 109
CPH O/L TEMP 139
HEAVY DUTY CALCULATION

HP SYSTEM HEAT O/P MW : 147.05

LP SYSTEM HEATY O/P MW : 24.33
CPH SYSTEM HEAT OUTPUT :19.31
TOTAL HEAT OUTPUT MW :190.69
THERMODYNAMICAL
DESIGN OF HRSG
 OPEN CYCLE GAS TURBINE
HEAT FLOW DIAGRAM

POWER(30%)

FUEL EXHAUST
HEAT(67%)

LOSS(3%)
COMBINED CYCLE

100
Celsius

540
Celsius
 COMBINED CYCLE PLANT HEAT
FLOW DIAGRAM
45.9 %

GT
STG
POWER(30%)
POWER(15.9%)

STACK LOSS(14%)
FUEL(100%) GAS TURBINE
EXHAUST CONDENSER
HEAT(67%) LOSS(34.3%)

MISC.LOSS(3%) MISC.LOSS(2.8%)
SINGLE PRESSURE HRSG

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
Close Approach / Zero Approach Design
Issues Involved

 Flashing in FCS

 Erosion of valve seat

 Two Phase flow in connecting links

 Erosion of pipes

 Water Hammer
 Methods for Close / Zero Approach
 FCS in between Drum and Economiser
 Better Seat Materials to avoid Seat
Erosion
 Economiser Design for BFP Shut-off
Pressure
 SRV on Economiser
 Economiser Recirculation
 Recirculation pumps with C&I
 Bypassing the Cold Water
 Last Pass Vertically Upward
FCS In Between Drum and Economiser
FCS
Drum

Economiser

Feed Water In
 Stack Temperature

 Lower stack temperature - higher efficiency

 Lower stack temperature achieved by

 Introduction of CPH/MUH
 Steam generation at Dual /triple pressure levels

 Dictated by
 Acid dew point (for fuels with sulphur)
 Water dew point (for fuels without sulphur)
 Effect of steam parameters on
HRSG exit gas temperature-NEED OF MULTI
PRESSURE
Main Steam Main Steam Drum Exit Gas temp
Pressure temperature Sat. temp

kg/cm2(g) °C °C °C

7 Sat 170 149

11 Sat 179 156
18 Sat 208 162
28 Sat 231 178
28 315 232 186
42 Sat 254 189
42 400 256 204
 Multiple Pressure Levels
 Single Pressure Non Reheat
 % Efficiency : ~35-38

 Dual Pressure Non Reheat

 % Efficiency : ~48-50
 Widely Used

 Triple Pressure Non Reheat

 % Efficiency : ~50-52

 Triple Pressure Reheat

 % Efficiency : 55+(Single RH) / 60+ (Double RH)
 For Advanced Class Gas Turbines
Dual Pressure System
Arrangement
 Temperature Profile – Single Vs
Dual Pressure HRSG
600

Temperature (Deg. C)
500
400
300

DESH
200
100
SH-II SH-I Evap Eco
0

600

500
TEMPERATURE

400
D
E
S
U
P
300 E
R
H
E
A
200 T
E
R

100

HPSH2 HPSH1 HPEVA HPECO2 LPSH LPEVAP HPECO1 LPECO CPH

P
0
WHY MULTI PRESSURE PRESSURE HRSG

HRSG Temperature Profile

Temperature

Flue Gas
Superheater
Pinch Point
Approach Point
Evaporator
Economiser

HRSG Inlet HRSG Outlet

Triple Pressure Reheat System
Arrangement
 With Reheaters

 RH Steam temperature same as SH steam temperature

 RH and SH modules alternately

 55% CCP efficiency achieved with single reheat

 More than 60% efficiency with double reheat

 HRSG with Single Reheat Design
CRH Steam In

HP Drum
HP Steam Out

HRH Steam out

RH SH RH SH HP Evaporator
 Temperature Profile – Single Vs Triple Pressure HRSG
600

Temperature (Deg. C)
500
400
300

DESH
200
100
SH-II SH-I Evap Eco
0

600

500
TEMPERATURE(Deg. C)

400

300

200
DESH

100
HPSH2 HPSH1 HPEVA HPECO5 IPSH HPECO4 IPEVAP LPSH HPECO3 IPECO HPECO2 LPEVA LPECO HPECO1 CPH
0
 Temperature Profile – Unfired Vs SF Fired HRSG
600
Unfired
Temperature (Deg. C)

500
400

300

200
100
SH-III Burner Screen SH-II DESH SH-I Evap Eco
0
900
800
700 Fired
Temperature (Deg. C)

600
500
400
300
200
100
SH-III Burner Screen SH-II DESH SH-I Evap Eco
0
Supplementary Firing Improves Efficiency
HRSG CONSTRUCTION
 Special Features of BHEL HRSGs
 Compact Design

 Use of High Frequency Welded High

Efficiency Spiral Finned Tubes

 Natural circulation Module Tube to Header

 Single / Multi pressure level

 Modular construction

 Fully drainable sections

 Complete internal insulation

 Module Construction Details

Modules: It consists of

1. Casing
2. Headers With Attachments
3. Spiral Finned (Serrated/Solid) / Plain
tubes
4. Vibration snubbers
- Module Spacer Box
- Module Spacer Bar
All HRSGs are designed as per IBR and materials used for
Manufacturing Pressure parts are as per ASME. Allowable Stress
values for these Materials are taken from ASME Sec-II, Part-D.

Vogt type HRSGs are further classified under the following

heads:
1.     Single/double/triple width HRSG
2.     Single/dual/triple pressure HRSG
3.     Top/bottom supported HRSG
4.     Unfired/supplementary fired (using duct burner) HRSG
Material Selection Criteria Based on Temperature
as per ASME
Temperature Material
Up to 427 Deg. C Carbon Steel
460 Deg. C A 588 Gr.A
428 to 482 Deg. C T1
483 to 533 Deg. C T12, P12, Gr.12
534 to 552 Deg. C T11, P11, Gr.11
553 to 577 Deg. C T22, P22, Gr.22
578 to 635 Deg. C T91, P91
Above 635 Deg. C Stainless Steel
HRSG
CONSTRUCTION
 Internal Insulation
Outer Duct Casing

Internal Insulation

Liner Plates

Flue Gas Path

Shop facilities
 Spiral Finned Tube
• Finned tubing used to increase heat transfer
• Two types - Solid fins and Serrated fins
• Serrated fins have higher heat transfer rate
 Modular
Construction
Single Row Module

Two Row Module

Shop facilities
 Vibration Snubber in Modules

Since modules are slender, it has the tendency to buckle.

To avoid buckling and to avoid vibrations, these snubbers are
provided at approximately every 3m height.

The Vibration Snubber Consist of

-Module Spacer Box
-Module Spacer Bar
 Special facilities

Facility created
for larger size
HRSG Module
Fabrication

Module Height – Upto 26 m

 HRSG Start-up
Considerations
 Temperature difference across thick
walled components

 Thermal stresses

 Pressure stresses

 Thermal stress plus pressure stress less

than max allowable stress
HRSG Start-up Considerations

 Facilities to limit temperature

difference (drum pressure rise rate)

 Venting steam through start-up vent

 Steam dumping through HP-LP

bypass system
HRSG Start-up Considerations

Load demand mode



• GT load raised & maintained such that

the GT exhaust temp. Is less than 400

°C.

• Heat input to HRSG is controlled through

stepped opening of diverter damper

 HRSG Start-up Considerations
 Temperature guided mode
• GT load is limited to a minimum
• Diverter full open towards HRSG
• HRSG steam production is governed
by raising GT load according to
allowable transients of the critical
component to a preset value
 HRSG Start-up Conditions
 Cold start -up
• After 48 hours shut down
• HRSG de pressurised
• Steam turbine cooled down below 160
°C
• Drum pressure < 10 %
 HRSG Start-up Conditions

 Warm start - up

• After 8 hrs shut down

• Drum pressure < 60 %

• Steam turbine temp. 160°C to 450 °C

 HRSG Start-up Conditions

 Hot start - up
• After 2 hrs shut down

• Drum pressure approximately 90 %

• steam turbine temperature > 450 deg

c
 HRSG Start-up Time
 Minimum time required
• Cold start - up approximate - 60 mts
• Warm start - up approximate - 30 mts
• Hot start - up approximate - 15 mts
 HRSG Start-up Time
 Typical Cold start up time

• Drum Pressure - Time (minutes)

• 80 ata - 60
• 100-110 ata - 90
 HRSG Start-up Considerations
 Base load units
• Cold starts - 300
• Hot starts - 1200
 Two shifting units
• cold starts - 1200
• Hot starts - 7800
 5 hot starts & 1 warm start per
week
HRSG Design Considerations
To Facilitate Smooth & Quicker Start -Up

• Large drum with adequate water holding

capacity and efficient drum internals

• Adequately sized downcomer piping.

• Elimination of tees & elbows wherever

feasible
HRSG Design Considerations
To Facilitate Smooth & Quicker Start -Up

• Multipass SH arrangement eliminating bottom

cross over connections ensures free downward

expansion of SH modules

• Top supported design facilitates free downward

expansion of all heat transfer sections

HRSG Design Considerations
To Facilitate Smooth & Quicker Start -Up

• Provision of expansion bellows wherever

penetration through duct casing is envisaged

• Single pass gas flow through HRSG without

any sharp bends in HRSG ducting

 SITE FEED BACK
 Startup curves
pressure
DD open

 ECO SRV lifting and FCS problem

GIPCL

 CPH charging

 CPH and D/A preservation

THANK
YOU