BILFINGER BABCOCK CZ s. r. o.

THE EXPERIENCE WITH SUCCESFUL EXECUTION OF HRSG

FOR AMBARLI PROJECT
Dipl. Ing. Radomr Nantl
19. 4. 2013
Important provider of steam generators and
power plant equipment
Bilfinger Babcock CZ

Long-time tradition, dating back to 1814

Since July 2011 member of the international engineering
and services group Bilfinger SE
Experience at implementing projects all over the world
Broad scope of activities and high degree of flexibility
Strong engineering expertise
Environmental friendly & state of art technologies
Quality and Health & Safety in focus

PL

CZECH REPUBLIC
Bilfinger Babcock CZ

DE SK SK
AT

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Product portfolio
Bilfinger Babcock CZ

New Built Service

Heat Recovery Steam Generators Reconstructions

Clean Biomass Fired Boilers Improvement of Operational

Characteristics
Coal Fired Boilers
Measurements and Diagnostics
Special Boilers
Spare Parts
Turnkey Plants
3D Laser Scanning

page 3
Content

Project Introduction
Basic Description of HRSG

Assembly Process

Special Features

Feedback & Conclusion

page 4
Project Introduction
Location of project
Project Introduction
Location of project
Project Introduction
Location of project
Project Introduction
Location of project
Project Introduction
Location of project
Project Introduction
Location of project
Project Introduction
Location of project
Project Introduction
Location of project

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Project Introduction
Scope of Services

Basic Design

Detail Design

Purchasing

Manufacturing

Delivery

Erection & Commissioning

Performance Tests

page 13
Project Introduction
Basic Design

Longitudal plane

Transversal plane

page 14
Project Introduction
Basic Design

Velocity and flue gas temperature before heating surfaces

page 15
Project Introduction
Basic Design

Streamlines in longitudal direction of HRSG

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Basic Description of HRSG
Principal Diagram

page 17
Basic Description of HRSG
HRSG Parameters

HP Steam System:
Nominal steam outlet temperature 540.0 C
Nominal steam outlet flow 78.1 kg/s
Nominal steam outlet pressure 115.0 bar(a)

Reheated Steam System:

Nominal steam outlet temperature 540.0 C
Nominal steam outlet flow 90.1 kg/s
Nominal steam outlet pressure 29.0 bar(a)

LP Steam System:
Nominal steam outlet temperature 195 C
Nominal steam outlet flow 8.0 kg/s
Nominal steam outlet pressure 4.0 bar(a)

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Assembling
Site Preparation

page 19
Assembling
Steel Structure

page 20
Assembling
Steel Structure

page 21
Assembling
Hot Beams with Hangers

page 22
Assembling
Erection of Modules

Transloading of 1/3rd module Lifting frame with 1/3rd of module

page 23
Assembling
Suspension of Module 9

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Assembling
Suspension of Modules

Welding of module parts header

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Assembling
Completion of Modules

page 27
Assembling
Side Wall Casing

page 29
Assembling
Side Wall Casing

page 30
Assembling
Inlet Flue Gas Duct Casing

page 32
Assembling
Inlet Flue Gas Duct Completion

page 33
Assembling
LP Drum

page 34
Assembling
IP Drum

page 35
Assembling
HP Drum

page 36
Assembling
Stack

page 37
Assembling
Connecting Piping and Headers

page 38
Assembling
Connecting Piping Between Modules

page 39
Assembling
Finishing of Work

page 40
Assembling
Boiler in Operation

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Construction phases

???
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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

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Construction phases

page 64
Weight summary

HP boiler drum: 116 t

IP boiler drum: 24 t
LP boiler drum: 38 t
Module 1: 141 t
Module 2: 194 t
Module 3: 313 t
Module 4: 142 t
Module 5: 79 t
Module 6: 191 t
Module 7: 187 t
Module 8: 103 t
Module 9: 153 t
Stack: 59 t
Flash tank: 4t
Total (incl. Steel Structure): 2 885 t
page 65
Weight Comparison
Weight Comparison
Model vs reality

page 68
Model vs reality

page 69
Special features

HRSG connected in open cycle?

?????

YES! IT IS TRUE!

via

DRY RUN OPERATION

Special features

material selection

hanging system stress

thermal expansion
- horizontal
- vertical
Special features

page 72
Special features

Stress analysis of tube sheet

page 73
Special features

Stress analysis of tube sheet

page 74
Special features
Special features
Feedback & Conclusion
Warm start-up curves

page 77
Feedback & Conclusion
Calculations versus Measuring

page 78
Feedback & Conclusion
Calculations versus Measuring

page 79
BILFINGER BABCOCK CZ s. r. o.

THANK YOU FOR YOUR ATTENTION

Dipl. Ing. Radomr Nantl
19. 4. 2013