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Heat RecoverySteam Generators

CAPABILITY BROCHURE

CLEANER FOSSIL FUELS PROGRAMME

CB014 MARCH 2004

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The DTI drives our ambition of

prosperity for all by working tocreate the best environment forbusiness success in the UK. Wehelp people and companies becomemore productive by promotingenterprise, innovation and creativity.

We champion UK business at homeand abroad. We invest heavily inworld-class science and technology.

We protect the rights of workingpeople and consumers. And westand up for fair and open markets inhe UK, Europe and the world.

CONTENTS

Introduction and Scope.........................................1

UK CAPABILITIES...................................................2

Equipment Manufacturers ....................................2

Utility HRSGs ..................................................... 2

Industrial HRSGs ............................................... 4

Project Developers.................................................5

Operation................................................................ 6

Economiser Steaming .......................................6

Dew-Point Corrosion .........................................6

Flexible Operation .............................................6

Economisers....................................................... 6

Evaporators........................................................ 6

Superheaters & Reheaters................................6

Attemperators.................................................... 7

Tube Damage..................................................... 7

Expansion Joints............................................... 7

Engineering, Consultancy and

Related Services ....................................................8

DIRECTORY.............................................................9

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1

CAPABILITY BROCHURE:

Heat Recovery

Steam Generators

INTRODUCTION AND SCOPE

Many industrial processes and powergeneration systems produce a high

temperature exhaust gas which, if releasedstraight to atmosphere, represents a largeloss of energy. For a typical gas turbine, theexhaust heat loss can be greater than 60% ofthe lower heating value (LHV) of the fuel. Inother industrial processes, the process itselfmay require that a gas stream be cooled.Heat recovery steam generators (HRSGs) can

convert heat in these exhaust gases to usefulenergy and hence improve process efficiencywith economic and environmental benefits.

HRSGs are employed in a

number of applications.

The larger units (utility

HRSGs) are used in utility

combined cycle gas

turbine (CCGT) power

plants, while medium-to-smaller units (industrial

HRSGs) are used with

other engines and in

various industrial

processes.

Utility scale HRSGs

operate at high pressure

(HP) steam conditions of

up to 124bar/565C with

the associated CCGTs

delivering electrical power

with a net efficiency

approaching 60%. During

the last ten years, over 30

CCGT power plants have

been built and are

operating in the UK. This

has helped the UK to

develop a great deal of

expertise in the design,

manufacture and

operation of utility

HRSGs. The UK has also

been involved in the

development of HRSGs

for use in integrated

gasification combined

cycle (IGCC) power plant.

Industrial HRSGs generally

operate at lower steam

conditions and often

include provision for

supplementary or auxiliary

firing. Lower pressure

industrial boilers are

usually of shell (rather

than water tube) design.HRSG applications are

more diverse at the

industrial scale, eg

Figure 1. Little Barford CCGT plant with two vertical duct HRSGs

(courtesy of RWE Innogy)

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industrial gas turbines use essentially the same HRSG

technology as at the utility scale, while reciprocating engines

generating electricity on a small scale use small HRSGs to

usually recover low-grade heat as hot water from the engine

cooling circuit to operate in combined heat and power (CHP)

mode. Higher-grade heat may also be recovered from the

engine exhaust gas as steam using HRSGs. Heat recovery,using HRSGs, is also achieved from other industrial exhaust

gases such as glass/metallurgical furnaces, kilns, roaster

based plants, smelters and converters, coke ovens, and

solid/liquid/gas waste incinerators. There is a long tradition of

various applications of industrial HRSGs in the UK.

In the current competitive HRSG market, UK companies

have been involved in licensing agreements and collaborative

partnerships to compete in the global market. The continual

development of new technologies, eg once-through

technology, the effects of flexible operation, new forms of

gasification and the use of HRSGs in novel low emission

power cycles are also vital for new business.

UK CapabilitiesEQUIPMENT MANUFACTURERS

The UK has a long history in the design, manufacture and

use of HRSGs, extracting heat from, eg gas turbine

exhausts, reciprocating engine exhausts, flue gases from

waste incineration plant, petrochemical plants and process

plants for combined heat and power. The growth of CCGT

plants for power generation in the UK over the last 15 years

has given an opportunity to local industry to apply its

expertise in the design and manufacture of large HRSGs for

utility power generation.

Utility HRSGs

A utility HRSG is essentially a counterflow heat exchanger

consisting of a series of superheater, boiler (or evaporator)

and economiser tube sections, arranged from the gas inlet to

the gas outlet to maximise heat recovery from the gas

turbine exhaust gas. The heat transfer rate on the water side

of the tubes is far greater than the transfer rate on the gas

side. The outside heat transfer rate is said to be controllingand is therefore responsible for the overall heat transfer rate.

In an HRSG, this overall heat transfer rate is lower than that

2

This brochure focuses onUK companies, andresearch institutions and

universities that havedeveloped expertise inthe field of HRSGs. Itincludes equipmentmanufacturers, projectdevelopers, operators,engineering andconsultancy companies,and those universitieswith R&D departments

investigating variousaspects of HRSGtechnologies.

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in a fired boiler due to the lower flue gas

temperatures and the reduced effect of

radiation. In order to increase the rate of

heat exchange, the surface area on the

outside of the tubes is increased by finning.

An HRSG may have either a horizontal or a

vertical gas pass. In the first case, the gas

turbine (GT) exhaust is ducted horizontally

through the HRSG casing, before being

turned vertically up a stack. The vertical

evaporator tubes allow natural circulation. In

the second case, when the gas pass is

vertical, the evaporator tubes are horizontal

and circulation is usually forced to ensure a

more consistent flow of water. However,

natural circulation HRSGs have been built

with vertical gas flows and horizontal

heating surfaces. The two design types have

their own advantages and disadvantages,but both manage to compete successfully in

the same markets. Both hold similar records

for plant life and reliability, and there is no

marked cost difference between them.

To maximise heat recovery, the final flue gas

temperature should be as low as possible

(whilst remaining above the dew point). To

maximise steam turbine efficiency, thesteam pressure and temperature should be

as high as possible. The temperature of the

evaporator section is the saturated water

temperature, which increases with pressure.

Increasing the pressure therefore increases

the temperature at which heat exchange is

occurring, which limits the amount of heat

recovery. The way around this conflict is to

use a multi-pressure system.

With a dual pressure cycle, the high-pressure

circuit ensures high steam pressure delivery

whilst the low-pressure circuit ensures that

maximum heat is extracted from the GT

exhaust. Efficiency can be further enhanced

by adding more pressure levels, but extra

capital cost will be incurred and, in practice,

no more than three are generally used.

Steam, which has initially passed through the

high-pressure section of a steam turbine, may

be reheated, improving the lower pressure

end of the steam turbine performance. The

overall cycle efficiency of a triple pressure

system with reheat is typically 3% higher

than that of a single pressure system.

As a gas turbine exhaust contains sufficient

oxygen to support further combustion

(approximately 15% w/w), additional burners

may be positioned in the exhaust stream

across the transition duct to allow

supplementary or auxiliary firing.

Supplementary-fired HRSGs have additional

firing capability to increase the flue gas

temperature, which, in turn, increases steam

production and raises the superheated steam

temperature. The normal exhaust temperature

of a large GT is up to ~600C. This temperaturecan be raised to ~815C by supplementary

firing in a standard HRSG design. Higher

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Figure 2. HRSG modules stored at Thermal

Engineering International prior to export (courtesy of

Thermal Engineering International)

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temperatures up to around 1100C are possible

if a refractory lining is fitted. Above this

temperature, water cooled walls are needed.

An increase in exhaust gas temperature to

~815C is associated with an increase in steam

production of approximately 50%.

Supplementary-fired HRSGs allow steam

to be generated in the HRSG when the gas

turbine itself is not in operation. This allows

maintenance to be undertaken on the gas

turbine whilst still generating electricity with

the steam turbine. A separate air inlet duct

is needed in this case.

Leading suppliers of large HRSGs for utility

applications are Alstom Power, Mitsui

Babcock, Nooter/Eriksen, and Thermal

Engineering International.

Industrial HRSGs

A wide variety of operating conditions and

applications has resulted in a variety of

designs and specialised equipment additions

for industrial scale HRSGs. For example:

In some process applications, the gas

may have a high dust load and the dust

chemistry will influence the build-up of

deposits on tube surfaces. Online

cleaning mechanisms (eg soot blowers)

may be required and allowances for the

reduction in heat transfer rate due to

deposits must be made.

Construction materials must be

appropriate to the chemical composition

of the hot gas.

In CCGT applications, the hot exhaust gas

pressure is always low to minimise the

GT backpressure, whilst it may be high in

process-integrated applications.

Process exhaust gas temperatures may be

far higher than GT exhaust temperatures,

necessitating the use of refractory linings

or water walls. The latter may be

advantageous in applications where the

exhaust gas is corrosive and would attack

a refractory lining or where there is a high

degree of supplementary firing.

Very high availability of steam production

may be required for a downstream

process, demanding the installation of

burners for auxiliary firing.

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Figure 3. Eight HRSGs at a power station in North East England (courtesy of Nooter/Eriksen)

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Many water tube industrial HRSGs are

broadly similar in design to utility-scale units.

They are usually simpler, often having just a

single working pressure and no reheat. In

some applications in which steam pressures

and flows are lower, it is possible to use a

smoke tube design. This is relativelysimple, easy to construct and has lower

capital cost. It removes the need for a

separate steam drum, and the need to

consider circulation. It is therefore, favoured

in many smaller scale applications,

especially in small-scale CHP schemes, for

which factory-built package units are

available. The smoke tube design is also

favoured in process applications where

there is a high gas-side pressure.

However, smoke tube designs are limited in

their steam flow and pressure capabilities

compared with the water tube design and

the multitude of small diameter gas passes

means that they are unsuitable for

applications where there is a high dust load.

Currently, once-through steam generators

(OTSGs) are used more widely at the

industrial scale than the utility scale. In the

OTSG there is no steam drum for the

separation of steam and water. Feedwater is

evaporated and superheated without

circulation.

Industrial HRSGs are supplied by BIB

Cochran, Innovative Steam Technologies,

ME Engineering, Nooter/Eriksen,

Thermal Engineering International and

Wellman Robey.

PROJECT DEVELOPERS

A number of UK companies are able to

supply a wide range of services for the

development of projects involving

application of HRSGs. Companies capable

of offering full turnkey services for utility

plant include Alstom Power, Mitsui

Babcock, Mott MacDonald, PB Power,

Powergen UK and RWE Innogy. Various

support services relating to development of

HRSG-related projects are also offered by

Mott MacDonald, PB Power, Powergen

UK and RWE Innogy.

5

Figure 4. Four units of once through HRSGs on apower barge (courtesy of Innovative Steam

Technologies)

Figure 5. PB Power served as owners representativeduring the construction of the Seabank Power Station

in Bristol (courtesy of PB Power)

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OPERATION

The main operational issues experienced by

users are usually dependent on HRSG

design, quality of fabrication and supplier

experience. These issues are:

Economiser Steaming

Steam locking is a risk on horizontal gas-

flow designs, some of which have high

points in the tubing that cannot be vented

adequately. This can result in differential

tube expansion, poor drum level control,

chemical deposition (with an associated

corrosion risk) and economiser under-

performance.

Dew-Point Corrosion

External dew-point corrosion due to low

back-end temperatures on start-up and

during low load operation is a risk on

preheaters and, to a lesser extent, on

economisers. Typically, a pumped

condensate preheater recirculation system

can be used to maintain inlet temperature

above acid dew point.

Flexible Operation

Flexible operation introduces a greater

number of events where differential

temperatures exist within boiler

components, and this reduces the fatigue

life of the boiler. Some of these effects are:

Economisers

Thermal fatigue and corrosion fatigue of

economisers is usually start-related and

exacerbated under a flexible operation

regime. During start-up, it takes some time

for the drum swell to subside after steam

formation has commenced. The economiser

header and tubes may, therefore, be 100-150C above the temperature of the

feedwater by the time the feedwater is

required. Depending on the header

geometry, these mechanisms may be

substantial enough to cause low cycle

fatigue.

When a unit is boxed-up (during an

overnight shutdown, for example), heatradiates from the hotter components to

cooler ones such as the economiser and

preheater. The economiser and preheater

tube banks warm up as heat is redistributed

within the boiler, particularly if a stack

damper is used to reduce cooling rates and

pressure decay whilst off-load. On start-up,

thermal down-shock can occur on the

internal surfaces of economiser and

preheater headers as relatively cold

feedwater enters these components.

Thermal stratification within the economiser

headers can occur when off-load. A

temperature differential is established in the

vertical plane causing the upper part of the

header to expand relative to the lower part,

leading to header hogging and loading of

the stub-to-header welds.

Evaporators

There can be difficulties in maintaining

drum levels within allowable limits on start-

up; using different drum levels for different

start types can make this more

manageable. The drum is usually the

thickest-walled component and therefore

most vulnerable to stresses due to through-

wall temperature differentials. The use of

the newer higher strength alloys allows

thinner sections to be used, reducing this

problem. However, the use of once-through

technology will have a greater effect, as it

removes the need for a drum.

Superheaters & Reheaters

As the first heat exchanger in the gas path,

the final stage superheater inevitably seesthe most severe temperature cycling. On

utility-scale units, the GT exhaust

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temperature can increase from 80C to

450C in five minutes. This results in high

stress concentrations in the headers at the

tube stub positions and uses up the fatigue

life of the component.

The tubes can reach temperatures abovethose experienced during normal operation

and so may be at risk of creep (as well as

fatigue) damage during this period. The ramp

up in temperature is followed by a

temperature drop when the drum pressure

has risen sufficiently to initiate a substantial

cooling steam flow.

Reheaters are also susceptible to thermal

fatigue damage on cold starts. Gas turbine

purge sequences rapidly cool the HP

superheater (and reheater, if applicable),

particularly on a hot restart following a GT

trip. This results in condensate formation,

which can collect in, and thermally shock the

lower headers/tubes of horizontal gas-flow

HRSGs. Damage is exacerbated if drains are

not sized or operated adequately to remove

the condensate at the rate that it forms.

The unequal distribution of this condensate

can result in tube distortion and differential

expansion between different parts of the

header, which, depending upon the

flexibility of the stub to header

attachments and/or header support

system, may result in substantial loads on

the stub-to-header welds.

Attemperators

Attemperator sprays are used to control the

temperature of the main steam leaving the

final superheater/reheater outlet header.

Poor attemperator control can result in

quenching of superheater/reheater headers,

tube distortion and damage to downstream

pipework. Attemperators can be particularly

problematic on start-up or when an HRSG isbeing operated at part-load. Modern multi-

nozzle, piston-controlled sprays or similar

sophisticated systems allow finer

attemperation control and reduce the risk of

these problems.

Tube Damage

Tube fretting is the abrasion of tubesagainst the tube sheets through which they

pass. It may cause wall thinning and

eventual failure. Fretting can occur during

expansion/contraction on start-

up/shutdown, particularly where finned

tubing is used and/or where tube or tube

plate distortion has occurred. This may also

result in increased stress on the stub-to-

header welds.

Tube failures have also resulted from gas

bypassing via the sides of the HRSG casing.

Bypassing leads to a reduction in HRSG

thermal performance, casing distortion and

excessive heating of the wing tubes

downstream. It can also have an adverse

effect on the water/steam-side chemistry of

evaporator tubes. The correct positioning

and construction of tube sheets and baffles

reduce this problem.

Expansion Joints

Gas duct fabric expansion joints are

typically located at the HRSG inlet, the

outlet to the main stack and, if applicable,

at the bypass stack inlet. Expansion joints

often represent the most pressing obstacle

to more flexible operation, as low cycle

fatigue exacerbates existing defects and

can lead to the creation of new ones. High

temperature fabric expansion joints are

often of relatively complex design and

experience onerous operating conditions.

Large temperature differences between the

inner and outer flanges of a joint may occur,

particularly during start-up, and this can

result in steelwork deterioration and

subsequent fabric damage. More severedefects have been experienced on square

joints than on round joints - square joints

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inherently tend to concentrate stresses atcertain points within the frame.

With over 30 CCGT plants using large

HRSGs operating in the UK, the UK has

extensive experience in their operation.

Mott MacDonald, Powergen UK and RWE

Innogy can offer valuable services and

advice on proper design and operation of

HRSGs to avoid many of these problems.

ENGINEERING, CONSULTANCYAND RELATED SERVICES

The UK has a wide range of engineering and

consultancy capabilities in HRSGs that

include:

feasibility/option studies

preparation of Enquiry and Specifications evaluation of tenders to ensure

commercial and technical compliance

detailed design assessment to identifypotential problems

review of design submissions

new plant development, supply and

installation

site supervision and commissioning

plant operation and maintenance

plant condition and performance

assessments

project management

operations support and training overhauls, repairs and refurbishment

research and development (R&D).

ME Engineering, Mitsui Babcock, Mott

MacDonald, PB Power, Powergen UK and

RWE Innogy offer engineering and

consultancy services. The Universities of

Sheffield and Cranfield are active in HRSG-

related research.

8

Figure 6. HRSG and gas turbine exhaust transition under construction at Teesside (courtesy of PB Power)

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Alstom Power LimitedPerformance Projects Derby

Sinfin Lane

Derby

DE24 9GH

Tel: +44 (0)1332 276000

Fax: +44 (0)1332 276001

e-mail:

[email protected]

Web site: www.alstom.com

Performance Projects Derby, a part of

Alstom Power, offers:

Steady state and off-design analysis and

refurbishment of thermal power plants.

Pressure component design and

compliance with the European Pressure

Equipment Directive.

Mechanical and structural integrity and

analysis of boiler steelwork, duct systemsand associated systems.

Complete control and instrumentation

package to current international standards.

Alstom Power also offers other key services,

eg project development relating to HRSGs.

BIB Cochran Boilers Limited

Newbie WorksAnnan

Dumfries & Galloway

DG12 5QU

Tel: +44 (0)1461 202111

Fax: +44 (0)1461 205511

e-mail: [email protected]

Web site: www.bibcochran.com

BIB Cochran Boilers has been manufacturing

boilers for UK and overseas markets for more

than 50 years, using solid, gaseous and liquid

fuels as well as HRSGs using exhaust gases

from industrial processes. Cochran HRSGsare supplied as a complete package with

feedpumps, controls and all necessary valves

and fittings, and are used for various

industrial applications.

Innovative Steam Technologies

60 Lombard Street

London

EC3V 9EATel: +44 (0)20 7464 8461

Fax: +44 (0)20 7464 8764


Web site: www.otsg.com

Innovative Steam Technologies (IST)

engineers and manufactures once-through

steam generators (OTSGs) to recover the

heat from the gas turbine exhaust stream.

IST is owned by AECON. AECON is the

largest Canadian construction company with

revenues of over $1 billion per year.

IST is the only proven manufacturer of once-

through heat recovery steam generators in

the world. ISTs OTSG enjoys numerous

advantages over conventional drum-type

heat recovery steam generators including

the following:

Simple operation - steam drums and

complex control systems are eliminated

making the OTSG capable of remote

attended or unmanned operation.

Simple and economical site installation

that minimises site costs and associated

project risks.

Capable of dry operation, therefore a

bypass stack is not required and the

steam system can operate independently

of the gas turbine.

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More efficient due to elimination of a

bypass stack and associated leakage as

well as blowdown losses.

Chemical injection to the steam drum is

not required, therefore this system is

eliminated.

Due to minimal instrumentation anddrainability, a building enclosure is not

required in cold climates. This eliminates

a costly enclosure from the project.

Low installation and life-cycle costs.

The above characteristics make the OTSG

ideal for the following applications:

Heat recovery in combined cycle and

cogeneration plants.

Heat recovery utilising the waste heat

from natural gas pipeline compressor

drives.

Heat recovery for steam injection for gas

turbine NOx control, power augmentation

and cooling purposes.

Heat recovery for barge and marine based

combined cycle plants.

IST currently has sold 90 OTSGs and

installed 70 in four continents (some units

are in various stages of construction). ISTs

technology has been examined and

accepted by many customers. The

following is a sample of some of our

current customers:

NEL Power, UK

Calpine, USA

Altek Alarko, Turkey

Alstom (Formerly ABB Power Generation),

Puerto Rico

GE Power Systems, USA

TransAlta Utilities, Canada, USA, New

Zealand

TransCanada PipeLines, Canada

Westcoast Energy, Canada

Solar Turbines, USA, Australia

GE Nuovo Pignone, Italy

Our size range currently handles gas

turbines from 5 to 60 MW for combined

cycle and cogeneration applications and the

entire gas turbine range for steam

injection/cooling applications.

ME Engineering Limited

Springfield House

Springfield Road

Grantham

Lincolnshire

NG31 7BG

Tel: +44 (0)1476 584300

Fax: +44 (0)1476 584301


Web site: www.me-engineering.co.uk

ME Engineering supplies industrial heat

recovery systems and fired boilers/heaters

worldwide.

Waste heat may be recovered into steam,

hot water, water/glycol and thermal oil

systems. Typical waste heat sources include

gas turbine exhausts, reciprocating engine

exhausts, waste incineration plant flue

gases, petrochemical plants and process

plants. ME Engineering can offer assisted

circulation, natural circulation and once

through designs of HRSG, with

supplementary or auxiliary firing if required.

ME specialises in systems for upstream oil

and gas projects requiring heat recovery

units behind gas turbines.

ME undertakes project management,

design, engineering, manufacture, assembly,

supply, installation, commissioning, testing

and servicing of group products. ME has an

international network of own and group

company offices and operates globally.

ME Engineering has ISO 9000 accreditation

and can manufacture to a number of design

codes such as BS, ASME, ISO and TRD.

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Mitsui Babcock

Porterfield Road

Renfrew

Renfrewshire

PA4 8DJ

Tel: +44 (0)141 886 4141

Fax: +44 (0)141 885 3204e-mail: [email protected]

Web site: www.mitsuibabcock.com

Mitsui Babcock is recognised as a leading

original equipment manufacturer and

contractor in HRSG plant supply and

aftermarket services, providing a

comprehensive portfolio from engineering

and field services, to replacement plant and

components to power plant operators.

Activities covered include:

new plant development, supply and

installation

design studies (eg repowering,

flexibility etc)

overhauls, repairs and refurbishment

operational maintenance and energy

management

commissioning, operations support and

training.

Mitsui Babcocks unique combination of

technical expertise in design and supply

coupled with extensive experience in site

repair & maintenance, allows it to deliver

complete solutions from plant selection

through upgrades and retrofits to life

extensions and full plant refurbishment.

Mitsui Babcocks capabilities embrace many

areas of CCGT and CHP plant, gas and steam

turbines, HRSGs and balance of plant (BoP).

Mitsui Babcocks engineering capability

covers all aspects of project engineering,

providing full technical support from process

design through to plant commissioning. The

company has developed state of the artanalytical methods to address technical

issues, eg defect assessment, changes in

operating regime, plant performance

problems, etc.

The tools used to improve operating

procedures, efficiency, maintainability,

availability, integrity and reliability include:

boiler and BoP flexibility improvements

(structural, mechanical and control &

instrumentation)

auxilliary or supplementary firing projects

(full turnkey, performance and integrity

assessments)

water chemistry and process design

reviews to identify the causes of

premature tube failures.

Mott MacDonald Limited

Victory House

Trafalgar Place

Brighton

BN1 4FY

Tel: +44 (0)1273 365000

Fax: +44 (0)1273 365100


Web site: www.mottmac.com

Mott MacDonald, an international company

based in the UK, is one of the worlds

largest multi-disciplinary engineering

consultancies. Mott MacDonald has been

able to provide world class consultancy

services in the power sector since Ewbank

Preece, the UKs leading power and

communication consultancy, joined the

Group in 1994.

The companys experience with heat

recovery systems for combined heat and

power applications, covers almost 40 years

of engineering excellence. Mott MacDonald

has considerable experience with all types

of heat recovery steam generators in a

variety of applications: vertical or horizontal

arrangement, natural or assisted circulation,with or without supplementary firing, and

increasingly with flexible operating regimes.

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Mott MacDonalds energy-related services

cover all aspects of power generation from

preliminary economic studies through

conceptual aspects, engineering, design and

specification, environmental considerations,

project engineering and management, site

supervision and commissioning to plantoperation and maintenance. We also provide

on-going consultancy services to clients

throughout the commercial operational life of

a power plant, which have included plant

condition and performance assessments.

In addition to the traditional consultancy

services, we also provide detailed design

services to turnkey contractors supplying

simple cycle, CHP, combined cycle power

generation and desalination projects being

developed worldwide.

Nooter/Eriksen-CCT Limited

Westleigh House

Wakefield Road

Denby Dale

Huddersfield

West Yorkshire

HD8 8QJ

Tel: +44 (0)1484 866466

Fax: +44 (0)1484 866179


Web site: www.ne.com

Nooter/Eriksen is one of the leading

suppliers of HRSGs (industrial and utility) in

both the domestic and overseas markets.

Scope includes design, manufacture, supply,

erection and commissioning.

PB Power

Amber Court

William Armstrong Drive

Newcastle upon Tyne

NE4 7YQ

Tel: +44 (0)191 226 1899

Fax: +44 (0)191 226 2104e-mail: [email protected]

Web site: www.pbpower.net

PB Power has engineered a wide range of

projects which encompass the use of heat

recovery steam generators as part of apower generation facility. Recently a large

number of gas-fired combined cycle power

plants have been constructed which have

incorporated either horizontal or vertical

HRSG arrangements to utilise the waste

heat from the exhaust of a gas turbine in

single, double and triple steam pressure

arrangements. In some installations,

provision has been included within the

HRSG design for the installation of selectivecatalytic reduction systems to control

emissions of nitrogen oxides. In addition to

Figure 7. HRSG at Barry Power Station (courtesy of

Nooter/Eriksen)

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the conventional types of HRSG, which

incorporate a steam drum, PB has also

engineered a small power station which

includes the use of once through boilers.

PB has engineered projects which

incorporate heat recovery steam generatorsas part of waste-to-energy plants, where the

energy in the hot gases from the combustion

of waste is recovered to produce electricity.

These HRSGs have typically been derived

from conventional boiler technology, being

arranged with a series of vertical flue gas

paths, but there are horizontal designs

available which can be used to minimise the

visual impact of such plants. PB Power offers

the full range of consultancy services to

potential purchasers and operators of HRSGs.

These services start with assisting a client in

the appropriate selection, inspection service

during manufacturing and erection, project

management, performance testing and

expert reviews.

Powergen UK plc

Power Technology

Ratcliffe-on-Soar

Nottingham

NG11 0EE

Tel: +44 (0)115 936 2362

Fax: +44 (0)115 936 2363


Web site: www.powertech.co.uk

Power Technology is the centre of

engineering, scientific, and environmental

expertise within the Generation Business of

Powergen UK. It provides specialist technical

services in every aspect of plant acquisition,

development, construction, operation and

maintenance to a worldwide customer base.

Services are supplied from Power

Technologys base on the Ratcliffe-on-Soar

power station site near Nottingham, wherethere are around 230 highly skilled, in-house

technical specialists.

Power Technology produces a range of

sophisticated products supporting plant

operation and management, whilst our R&D

programme delivers commercially focused

solutions and furthers our core competencies.

We provide advice and consultancy servicesworldwide to:

a wide range of utility companies

IPPs

large energy users

government and funding agencies, including

the World and Asian Development Banks,

the European Bank for Reconstruction and

Development, and EU programmes.

Power Technology provides technical and

engineering support for a large number of

CCGT projects and smaller CHP projects

including the HRSGs. Power Technology has

experience of all the leading HRSG

manufacturers, and support to customers

includes specification and tender

assessment, site inspections, resolving a

wide range of operational problems,

modification to pressure parts, ductwork

and supports, and operating procedures.

Although based in the UK, we also have

wide experience abroad, including plants in

Spain, Portugal, Hungary, India and the USA.

We are independent of manufacturers and

our advice is objective and unbiased.

Powergen has a team specialising in HRSGs,

mainly for gas-fired applications, but also in

oil and naphtha fired applications, and we are

actively tracking IGCC development. Power

Technology led the recent HRSG Technology

Status Review for the DTI and also carried

out the IGCC Technology Status Review in

1998. Our lead engineers have ten years

experience of utility-scale HRSG design and

operation. The company also has experts in

all the associated areas, including gas and

steam turbine design, materials technology,corrosion and water chemistry, combustion

systems (eg auxiliary firing), etc.

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RWE Innogy

Windmill Hill Business Park

Whitehill Way

Swindon

Wiltshire

SN5 6PB

Tel: +44 (0)1793 877777Fax: +44 (0)1793 893861


Web site: www.rweinnogy.com

RWE Innogy is a UK-based integrated energy

company whose core businesses are energy

production, retailing, operations and

technology, supported by an experienced

trading function, and asset management

business with a flexible, cost-efficient portfolio

of around 8000MW of UK gas, coal and oil-

fired generating plant. Through acquisition and

organic growth, our retail business, npower,

has become one of the UKs leading suppliers

of gas and electricity to domestic consumers

and commercial and industrial users.

RWE Innogy has its home in the most

advanced and competitive power market in

the world. The company has emerged from

the break-up of a national monopoly to make

its mark as a power producer, trader and

retailer with global presence. Innogy is a

truly global company, building on the

experience gained in the challenging

transition from a highly regulated to a

liberalised electricity market.

RWE Innogys great depth of operations and

engineering expertise, developed on our

journey to commercial optimisation of our

assets, is available to power companies

around the world. Using a wealth of

experience built on over 20,000 man years

acquired on more than 60,000MW of power

plant, the company provides support and

specialist services to other power plant

operators around the world. The companys

expertise enables it to improve powerstation reliability and efficiency and

effectively manage environmental impact,

thereby delivering optimum commercial

performance. Its teams support every

aspect of a power project from planning,

consents, construction, commissioning,

through life-time operations and

maintenance, to eventual decommissioning.

RWE Innogy has over 15 years of

experience in the CCGT field, which allows

us to provide a wide range of specialist

HRSG services, including:

feasibility/option studies to identify the

optimum solution for a particular application

preparation of Enquiry and Specifications

evaluation of tenders to ensure

commercial and technical compliance

detailed design assessment to identify

potential problems

review of design submissions

assessment of commissioning and

warranty issues

condition survey at scheduled outages

design review for change in operating

regime, typically increased flexibility, and

solutions to mitigate against potential

problems

performance modelling to assess the

benefits of plant modifications

provision of operations and maintenance

support.

Thermal Engineering International

Limited, Greens

PO Box 38

Calder Vale Road

Wakefield

WF1 5PF

Tel: +44 (0)1924 780000

Fax: +44 (0)1924 387320


Web site: www.tei.co.uk

TEI Greens has been at the forefront of

waste heat recovery since Edward Greenfirst invented the fuel economiser in 1845.

Expertise includes the recovery of waste

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heat from boiler and process flue gas

streams in the power generation, refining,

chemical, process and general industries.

TEI Greens is one of the largest

independent fabricators of boiler pressure

parts and HRSG components in Europe and

provides a wide range of heat transfer

solutions/products.

TEI Greens has an extensive reference list

and its product portfolio includes HRSGs,

economisers, air heaters, condensers,

feedwater heaters, package boilers, pressure

part fabrication etc, and can be found in

power generation plants, petro-chemical

industries, boiler plants and marine

applications in almost every part of the world.

Wellman Robey Limited

Newfield Road

Oldbury

West Midlands

B69 3ETTel: +44 (0)121 552 3311

Fax: +44 (0)121 552 4571

e-mail:

[email protected]

Website: www.wellmanrobey.com

Wellman Robey offers well-proven designs

of boilers for use with various solid, liquid

and gaseous fuels and HRSGs usingexhaust gases from various industrial

processes. These products come as a

complete package and meet the needs of

end-users with highly energy efficient

operation.

University of Cranfield

Power Generation Technology Centre

School of Industrial and Manufacturing

Science

Cranfield

Bedfordshire

MK43 0AL

Tel: +44 (0)1234 754253

Fax: +44 (0)1234 752473


Web site: www.cranfield.ac.uk

Cranfield University is a post-graduate

university with a strong industrial/engineering

bias. It was established ~50 years ago to

satisfy the post-graduate training needs of

the then developing aerospace industry.

Research interests have since developed to

encompass all aspects of industrial

manufacture and plant performance. The

Power Generation Technology Centre was

formed in 1998. The Centre brings together

activities in combustion and gasification

processes; gas turbines; heat exchangers;

materials and coating performance;

advanced gas cleaning; life prediction

modelling; process and flow modelling;

controls and environmental performance.

Within this scope, the Centre can provide

experience on materials in HRSG systems

and their impact on reliability, as well as

being able to simulate HRSG conditions atpilot scale for research purposes.

University of Sheffield

Figure 8. Erection of a vertical HRSG module at a UK

site (courtesy of Thermal Engineering International)

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Sheffield University Waste

Incineration Centre

Department of Chemical and

Process Engineering

Mappin Street

Sheffield

S1 4DUTel: +44 (0)114 222 7518

Fax: +44 (0)114 222 7501


Web site: www.shef.ac.uk/~suwic

Research activities in HRSG-related areas

include ultra-high temperature heat

exchangers (UHX) operating at 1200C at

40bar, composite tube structure with a

ceramic corrosion resisting material on the

appropriate surface to protect metal tubes,

separate/secondary heat exchanger operating

with a supplementary fossil fuel to ultra

superheat steam in existing power plant.

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Alstom Power

BIB Cochran Boilers

Innovative Steam Technologies

ME Engineering

Mitsui Babcock

Mott MacDonald

Nooter/EriksenPB Power

Powergen UK

RWE Innogy

Thermal Engineering Interntional

Wellman Robey

University of Cranfield

University of Sheffield

Equipme

nt

manufac

turer-utility

Equipme

nt

manufac

turer-industrial

Projectd

eveloper

Operatio

n

Engineeringand

consultancy

Research

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Crown copyright. First printed March 2004.

Printed on paper containing a minimum of 75% post-consumer waste. DTI/Pub URN 04/716

Further information on the Cleaner Coal Technology Programme,

and copies of publications, can be obtained from:

Cleaner Coal Technology Programme Helpline, Building 329,

Harwell International Business Centre, Didcot, Oxfordshire OX11 0QJ

Tel: +44 (0)870 190 6343 Fax: +44 (0)870 190 6713

E-mail: [email protected]

Web: www.dti.gov.uk/cct/

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