TYPES OF HRSGS

MODE OF HEAT INPUT

Unfired Supplementary fired Fully/Fresh air fired

CIRCULATION
Natural circulation Assisted / Forced circulation

PRESSURE LEVELS
Single pressure Multiple pressure

GAS FLOW DIRECTION

Vertical Horizontal

HRSG Vs CONVENTIONAL BOILER

HEAT TRANSFER Only convective - No radiation Rapid heating & cooling HEAT INPUT CONTROL Negligible in unfired mode Heat input depends upon GT load, ambient temp., etc Up to 50% in supplementary fired mode FLOW OF GAS THROUGH THE UNIT Almost constant - flow depends up on GT characteristics PERFORMANCE Largely depends on GTG performance

HRSG PROCESS DESIGN CONSIDERATIONS

PINCH POINT
Difference Between Saturation Temperature & Flue Gas Temperature Leaving Saturated Surface Lower Pinch Means Higher Heat Recovery - But Higher Capital Cost

APPROACH POINT
Difference Between Saturation Temperature & Feed Water Temperature Entering Saturated Surface Lower Approach Means Higher Heat Recovery - But Higher Capitol Cost Lower Approach Means Higher Steaming Potential Under Upset / Partial Load Condition

LOAD TURNDOWN AND CONTROL

Difficult In Unfired Units As Heat Source Is Uncontrolled Variable & Controllable in the supplementary fired range

HRSG PROCESS DESIGN CONSIDERATIONS

STEAM TEMPERATURE CONTROL RANGE
Very Narrow In Unfired Mode Comparatively Wider In SF Mode As TEG Reheat Temperature Has A Considerable Impact On Steam Temperature

SYSTEM DRAFT LOSS

Higher The Permissible Draft Loss - Lower Is The Capitol Cost - But Lower GT Output

SF FIRING TEMPERATURE LIMITATION

Restriction Due To Construction All Operating Modes To Satisfy This Limit

OPERATING MODES - UNFIRED /FIRED

Design Needs Checking For Worst Conditions In All Modes

HRSG - ABAN POWER

GENERATION CAPACITY:
SUPPLEMENTARY FIRED MODE - 168 TPH UNFIRED MODE - 105 TPH
STEAM PRESSURE - 110 Bar (a)

STEAM TEMPERATURE

- 542 + 5 0C

WITH INTEGRAL DEAERATOR AND MAKE UP WATER HEATER - ON GE FRAME 6FA GAS TURBINE

HRSG - ABAN POWER

SPECIAL FEATURES:

Low pinch recovery

and

approach

for

maximum

heat

Duct burner from R&V - Holland

High firing temperature up to 800 0C

Integral Deaerator Make up water heater - with bypass arrangement

Serrated finned tubes on staggered pitching

SALIENT FEATURES OF ABAN HRSG

NATURAL CIRCULATION SINGLE DRUM & ALL WELDED CONSTRUCTION

PRESSURE PART WELDS OUTSIDE GAS PATH

FLOW MODELLED DUCT DESIGN COLD CASING WITH INTERNAL INSULATION SPECIAL OVERLAPPING LINER ARRANGEMENT FULLY DRAINABLE SUPERHEATER INTEGRAL DEAERATOR & MUW HEATER

STAGGERED BARE TUBE SCREEN SOLID FINS & SERRATED FINS FOR TUBES SPECIAL TUBE SHEETS/SUPPORTS TOP SUPPORTED

HRSG ATTEMPERATION BRIEF OVERVIEW

What is Attemperation : It is the controlled cooling, in a steam boiler, of steam at the superheater outlet or between the primary and secondary stages of the superheater to get the desired final steam temperature. Temperature control is usually achieved by admitting a fine spray of water into the steam line, through an attemperator or desuperheater.

IN LINE SPRAY NOZZLE :

CROSS SECTION VIEW

50-100% CV Spray water from BFP

0-50% CV

Final steam temperature

steam temperature after attemperation

TE 202

steam temperature before attemperation

TE 201

TE 204

TE 203

Superheated steam to ST

Saturated steam from drum

Flue gas from GT + burner

SH 2

SH 1

-50

+
from design trend

SP

SP-PV(error)

slave controller

Master controller

50-100% CV

Spray water from BFP

SP-PV(error) manual

0-50% CV

SP
PV PV
TE 202 TE 201 TE 203

TE 204

Superheated steam to ST

Saturated steam from drum

Flue gas from GT + burner

SH 2

SH 1

FIRED MODE TREND

TEMP

X1 105 Y1 X2 115 Y2 X3 125 Y3 X4 135 Y4 X5 145 Y5 X6 155 Y6

FLOW TPH

UNFIRED MODE TREND TEMP

FLOW TPH

X1 80 Y1 X2 84 Y2 X3 91.7 Y3 X4 94.9 Y4 X5 97.5 Y5 X6 105 Y6

REASON FOR TWO CONTROL VAVLES. FIRST ONE IS 0-50% -6 TPH SECOND ONE IS 50 TO 100% - 27 TPH 1. When we are operating on part load, startup and shutdown spray requirement is minimum which is taken care by small(0-50%) valve. 2. When we are operating full load we need more attemperation which is catered by the big (50100%) valve. 3. Redundancy Even the failure of one valve we can control through another one.

WHY ATTEMPERATURATION GIVEN BETWEEN SH1 & SH2 Attemperation may be located before, between or after the superheater.

If it is located before : This will cause condensation of saturated steam from the boiler before it enters the superheater. So it is not the preferred location. If it is after the superheater : exact control of final temperature becomes difficult
So the Attemperation is kept between super heater 1 and superheater 2

THANK YOU