HRSG Overview

HRSG Overview

HRSG Systems - An Overview

HRSG Overview

Mechanical & Design Benefits

HRSG Overview

Section 1 - HRSG Inlet Transition Duct

High velocity and highly turbulent region 30 / 60 Inlet Duct Configuration Cold Casing design internally insulated and lined 12/16 gauge stainless steel inner liner (2.67mm / 1.52mm) 12.7mm (1/2) studs on 279.4mm (11) centers 6mm carbon steel (SA-36) outer casing Shipped in flat panels limited in size by shipping clearance.

HRSG Overview

Section 2 Superheaters/Reheaters

All welded header design to enhance reliability and lower life cycle costs Fully drainable & ventable to improve cycling capability Fully Top supported pressure parts allows for unrestrained thermal growth

HRSG Overview

Section 2 Superheaters/Reheaters

HRSG Overview

Section 2 Superheaters/Reheaters

Staggered or Inline Tube Pitch 38.1mm (1 1/2), 44.5 mm (1 3/4")

or 50.8mm (2) O.D. Tubing 88.9 mm x 88.9 mm (3.5x3.5) to 101.6 mm x 101.6 mm (4x4) tube spacing Serrated or solid finning

HRSG Overview

Section 3 Duct/Grid Burner System

3rd Party Engineered products, integrated into

the HRSG system. Locations in the HRSG Inter-staged firing or up-front firing natural gas, No. 2 oil, or heavy oil firing Horizontal/Vertical runner (element), side firing. Available with continuous/intermittent pilots, element isolation and a range of turndown. Burners, Fuel Skid, Cooling Air, BMS

Variety of fuels that can be fired:

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Section 3 Duct/Grid Burner System

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Section 4 - Burner Outlet Transition Duct

Cold casing design, internal insulation

with external stiffeners.

Internal Construction Options

Moderate firing < 730 C
ceramic fiber insulation with stainless steel internal liner

High firing > 730 C

Y-Bloc ceramic insulation module rated to 1090C without internal liner

Shipped in flat panels limited in size by

shipping clearance.

HRSG Overview

Section 5 Emission Control Systems

CO & SCR Systems

3rd Party Engineered products, integrated into the HRSG system. Modularized construction to reduce overall field installation labor Configured in the system to permit access for maintenance and catalyst replacement without removal of HRSG piping/structures.

HRSG Overview

Section 5 Emission Control Systems

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Section 6 Steam Drums

Drum shell/heads material in

accordance with boiler codes (SA-516 Gr 70 or SA-299) Hold retention duration determined by specification requirements Hinged manway access 305mm x 406mm minimum Two-stage steam purification system with primary separators and secondary dryers. Shipped as completed assembly including:
Nozzle connections, steam purification equipment and internal piping, drum saddles

HRSG Overview

Section 6 Steam Drums

Vortexes Used for Steam Separation and Circulation Alternative : perforated sheets

Chevrons Used for Steam Purification Alternative : mesh dryer

HRSG Overview

Section 7 HP, IP, LP Evaporators

All welded design Fully top supported pressure parts

pipe support (drum support) for HP rod and clevis supports for IP and LP

Staggered or Inline tube pitch 38.1mm (1 1/2), 44.5 mm (1 3/4") or 50.8mm

(2) O.D. Tubing 88.9 mm x 88.9 mm (3.5x3.5) to 101.6 mm x 101.6 mm (4x4) tube spacing Serrated or solid finning T-11, P-11 safe ends in upper bend areas in the LP evaporator to minimize flow assisted corrosion (FAC) damage

HRSG Overview

Section 8 - Economizers

All welded header design Fully drainable and ventable Fully top supported pressure parts Staggered or Inline tube pitch 38.1 mm (1-1/2) O.D. tubing 88.9 mm x 88.9 mm (3.5x3.5) tube spacing Serrated or solid finning

HRSG Overview

Section 9 - Feedwater Heater

Similar to other system Economizers in

design approach except:
Multiple tube and finning material options based on considerations of
oxygen pitting on the tube inside surfaces gas side fouling on the tube outside surfaces acid dewpoint considerations due to sulfur in the fuels

Splitted bottom header for first pass utilized in area of water entry to avoid damage due to thermal shock Can be fabricated from Austinetic or Ferritic tube material depending on requirements.

HRSG Overview

Section 10 - LP Steam Drum

Single or two-stage purification

system can be provided depending on facility requirements for steam

Sizing can be adjusted based

on specific needs of the facility.

HRSG Overview

Section 11 - Integral Deaerator

Horizontal or vertical
configurations Tray type or Spray and Tray type designs Connected directly to LP steam drum with no intervening valves. Floating Pressure operation.

HRSG Overview

Section 12 - Stack Assembly

Free standing, single wall design Designed to prevailing site

conditions based on civil/structural codes and ANSI STS-1. Isolation dampers and silencers can be included as necessary in the stack assembly.

Supplied in a variety of
arrangements based on shipping limitations and field construction needs.

HRSG Overview

Section 12 - Stack Dampers

Installed in stack
above breeching to reduce heat loss. Counterweigted to open + interlocked into DCS for safety. Shipped in match marked pieces after shop pre-assembly.

HRSG Overview

Section 13 - Ladders and Platforms

Stair access on one side, ladder

access on opposite side. Open bar type grating with supporting steel. 2 or 3 rail handrail system. Provided for access to equipment in the following areas:
main operating platform, both sides steam drum safety valve access stack access to emission ports and stack closure damper (if required) burner maintenance, flame observation

Fabricated in sections that can be

hot dip galvanized or painted

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HRSG Constructability

HRSG Packaging Options are based on evaluation

of shipping access, shop location and site capability to provide the most economical package
Modular Box Design Approach (highest degree of shop assembly) C-Section Modular Design Approach Field Modular Design Approach Field Platen Design Approach (lowest degree of shop assembly)

HRSG Overview

HRSG Constructability

Systems are provided in various configurations

to meet size and/or site limitations.
1 Wide Shop Modular C-Section Field Modular Field Platen X O O X O
X = standard O = optional

2 Wide

3 Wide

X O

HRSG Overview

HRSG Constructability

Modular Box Design Approach:

Highest degree of shop modularization with tube bundles shipped with the casings and supporting structures shop installed. Due to shipping limitations this approach usually only applies to Single Wide HRSG systems. In some instances, steam drums and interconnecting piping can be shop installed. Requires a detailed and thorough review of shipping clearances to assure access to the site.

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Loading of Modular Box for Transport

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Setting of Modular Box at Site

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HRSG Constructability

Field Modular Design Approach

Configuration based on maximizing the tube bundle size based on shipping limitations.
Heat transfer sections are prefabricated in modules (tube bundles) with interconnecting piping installed. Structural support steel and casing panels are shipped separtely from the modules which permits earlier site work and pre-assembly.

This approach can support either top loading or side loading of the tube bundles and can support any sequence of installation (left side first, right side first, front to rear, rear to front)

HRSG Overview

Field Modular Approach

Side Loading the first tube bundle in a Double Wide HRSG

HRSG Overview

Field Modular Approach

Close up of the showing degree of shop assembly

HRSG Overview

HRSG Constructability

Field Platen Design Approach

Configuration based on very low component weights to facilitate inland transportation.
Individual tube platens consisting of finned tubes and upper/lower headers are shipped loose. Interconnecting piping is shipped loose. Structural support steel and casing panels are shipped separtely from the modules which permits earlier site work and pre-assembly

Field assembly sequence is more restrictive due to installation hardware for the platens and would need to be determined prior to shipment of components.

HRSG Overview

Field Platen Approach

Uprighting and Installing a Platen

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Experience

Small-Size HRSG
Hamakua, Hawaii
2 Pressure Level with Bypass System Main Steam Flow: 33.4 t/h Press: 64.5 barg Temp: 513 C GT: GE LM2500 Fuel: Natural Gas

HRSG Overview

Experience

Mid-Size HRSG
New Brunswick, Canada Single Pressure with Fresh Air Firing Capability Main Steam Conditions Flow: 115 t/h Press: 43.8 barg Temp: 329C Future LM 6000 Fuel: Natural Gas

HRSG Overview

Experience

Large-Size HRSG
Samalayuca, Mexico 3 Pressure Levels with Reheater + Supplemental Firing Main Steam Conditions
Flow: Press: Temp: HP 158.3 t/h HP 102.4 barg HP 532C

GT: GE Frame 7FA Fuel: Natural Gas

HRSG Overview

Experience

Large-Size HRSG
Paris, Texas, USA 3 Pressure Levels with Reheater + Supplemental Firing Main Steam Conditions
Flow: Press: Temp: HP 226.8 t/h HP 124.3 barg HP 568 C

GT: GE Frame 7FA Fuel: Natural Gas