Heat Recovery Steam Generators Optimized for Any Application

8/10/2019 Heat Recovery Steam Generators Optimized for Any Application

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A FOSTER WHEELER HRSG

PRODUCING 70 MWe OF POWER AT THE LA R BIDA REFINERY SINCE 2009

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A LONG HISTORY WITHHEAT RECOVERY STEAMGENERATORSSince we supplied our rst HRSG to the Rio Pecos combined cycle plant (Texas, USA) in1958, we have advanced HRSG technology to a new level of thermal and mechanicalperformance, reliability and ease of maintenance.

With over 350 Foster Wheeler HRSGs in the eld today with millions of opera onalhours, Foster Wheeler HRSGs have developed a track record of reliable opera onand high customer sa sfac on for a wide range of combus on turbines.

We o er HRSGs for all applica ons ranging from large u lity combined cycle powerplants to small co-genera on and industrial facili es. For each applica on, our designsare tailored to meet the performance, reliability and cost goals of our customers.

Our support to our clients doesnt stop once a FW HRSG is opera onal. We provide abroad range of a er-market service to solve problems and improve performance andreliability of your HRSG. This applies to not only FW HRSGs, but to all HRSGs, no ma erwho the OEM.

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GAS TURBINES EXPERIENCE

ALSTOM / ABB SIEMENS

GT-8C, 10, 35 SGT, 600, 800

SGT5 - 4000F

GENERAL ELECTRIC SFT6 - 5000F

PG 6531, 6581, 7121, 9171 V64.3 , .4

LM 1600, 2500, 6000 V94.2, .3A

Frame 6, 6B, 6F, 6FA

Frame 7, 7B, 7E, 7F, 7FA SOLAR

Frame 9, 9E, 9F Cemtaur, H

Mars

MITSUBISHI

M501F, FD, SDA WESTINGHOUSE

501D5A

ROLLS ROYCE 501F

RB211 251 B6


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malca on: Abu Dhabi, UAEstomer: Samsung C&T Corp.rt-Up Year: 2014

RSG Capacity: 4 x 133 MWeT Model: GE 9FAel: Natural Gas

QurayyahLoca on: Saudi ArabiaCustomer: Samsung C&T Corp.Start-Up Year: 2014HRSG Capacity: 12 x 117 MWeGT Model: Siemens SGT6-5000FFuel: Natural Gas & Diesel Oi

FOSTER WHEELER HRSGs ARE DESIGNED FOR RELIABILITY AND LONG LIFE

Horizontal and verticaldesigns available forboth utility and industrialapplications

Steam temperatures upto 600C (1115F)

One, two or threepressure levels to suit anyapplication

Unfired, co-fired andfresh air fired forguaranteed steamproduction even withoutgas turbine operation

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OSITIVE CASING SEAL

LEX TUBE ASSEMBLY FULL PENETRATION TUBETO HEADER WELDS

UPFLOW / DOWNFLOWECONOMIZERS CIRCUITRY

OSITIVE LINERETENTION SYSTEM

SCR AVAILABLEON ALL DESIGNS

TUBE SUPPORT BANKSFOR THERMAL FLEXIBILITY

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SEAL SYSTEM

SUPPORT BEAM

SUPPORTSYSTEM

RISERMANIFOLD

Top supported coils forthermal mechanicalflexibility

Harps, C Sections ormodular fabrication fordelivery and field erectionflexibility

Large sized drain systemto reduce fatigue stressduring rapid start-up andshut-down

Extra strength fullpenetration welds tohandle fast transients andthermal shocks

CartagenaLoca on: Murcia, SpainCustomer: Repsol Petroleo S.AStart-Up Year: 2011HRSG Capacity: 1 x 15 MWeGT Model: GE PG6581Fuel: Natural Gas

DongducheonLoca on: Kyung-gi-do, Republic of KoreaCustomer: Samsung C&T Corp.Start-Up Year: 2014HRSG Capacity: 4 x 160 MWeGT Model: MHI M501JFuel: Lique ed Natural Gas

Norte IILoca on: Chilhuahua, MexicoCustomer: Samsung Engineering Co.,LtdStart-Up Year: 2012HRSG Capacity: 2 x 72 MWeGT Model: GE Frame 7FAFuel: Natural Gas

Manifa Cogenera onLoca on: Manifa, Saudi ArabiaCustomer: Tecnicas Reunidas PowerStart-Up Year: 2012HRSG Capacity: 2 x 62 MWeGT Model: Mitsubishi M501FFuel: Natural Gas


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S uperheaters designedwith oversized headers,downcomers, feeders anddrain systems to reducefa gue stress during rapidstart and shut down

Full radial penetra on welds areused for each transfer tube toheader weld so unit can tolerate fasttransients and thermal shocks withless risk of weld cracks and tearsassociated with lower quality welds

Flex tube designprovides inherentmechanical

exibility ensuringlong HRSG lifewhile enduring faststart-ups, upsetsand transients

Every heat transfertube in everysec on has at leastone tube bend

Op mally placed an vibra ongrid plates to minimize noise and

vibra on induced by perpendiculargas ow to tube bundles

HRSG modules hung from risersmanifold with simpli ed topsupported design to reduce space,erec on me and manpower

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OT ALL HRSG DESIGNS ARE THE SAME

Flexible bellow casing seal ensures leak- ghtconnec on while allowing free thermal expansionthrough all opera ng condi ons

Counter ow economizer maintains waterveloci es in tubes and e cient heat transferfor all opera ng condi ons

Economizer coils are drainable and ventablefor fast ll / drain while minimizing steamingduring start-up and shut down

Flow accelerated corrosion eliminated by useof high chrome tube materials in cri cal areas

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SCRs are available on all FW HRSGs toachieve very low NOx emissions

Designs allow for future addi on ofSCR components when requested

urata & Benghazi CCPPa on: Misurata & Benghazi,

Lybiaomer: Daewoo E&C-Up Year: 2010G Capacity: 4 x 117 MWe

Model: Siemens SGT5-4000F: Natural Gas & Diesel Oil

n CCPPon: Incheon, South Korea

mer: POSCO Engineering & Construc onp Year: 2010, 2011Capacity: 4 x 105 MWedel: Siemens SGT6-5000F

Natural Gas


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O-Sec ons

Fully casedtube bundle formodular assembly

Most cost e ec vefor units onemodule wide

C-Sec ons

Par ally casedtube bundles

Most cost e ec vefor HRSGs that aretwo modules wide

Modules

Individual tubebundles withoutcasing but with roof

Most common op onfor large combinedcycle HRSGs

Harps

Individual tubebundles withoutcasings or roof

Most coste ec ve forsmall HRSGs

FWs HRSGs ARE DESIGNED FOR TRANSP ORT AND SITE ERECTION FLEXIBI

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ur capability to supplyour HRSGs in di erentgura ons provides

most exibility to ourts, allowing them tomize site erec on workhe ul mate installedof their HRSGs.

global network ofufacturing facili es andneering centers, allowsprovide a quality

uct at very compe velevels and deliverys, no ma er where theect is located.

La RabidaLoca on: Huelva, SpainCustomer: CEPSAStart-Up Year: 2009HRSG Capacity: 1 x 119 MWe

GT Model: GE 6FAFuel: Natural Gas

Wacker ChemieLoca on: Burghausen, GermanyCustomer: Fortum Engineering GmbHStart-Up Year: 2001HRSG Capacity: 1 x 97 MWe

GT Model: GE Frame 9EFuel: Natural Gas

e Iberese - Somagueca on: Sines, Portugalstomer: Iberese / Somaguert-Up Year: 2010

RSG Capacity: 47 MWe Model: Siemens SGT-800

el: Natural Gas & Fuel Gas


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With more than a century of designing, fabrica ng, erec ng and star ngour own equipment, we have the experience and capability to assess yourHRSG, recommend improvements, and predict the impact on performance,reliability and opera on before any eldwork is started.

Service is an integral part of our business. Preven ve condi on monitoring,expert maintenance, rapid response repair work, and replacement partdeliveries are key factors in achieving maximum plant reliability and coste ec ve performance year a er year.

Through our service agreements, we provide comprehensive and coste ec ve maintenance programs, ranging from HRSG inspec ons to thesupply of parts and equipment including construc on services, resul ng inminimum unplanned repair work.

Our service is backed by a global network of manufacturing , engineeringand customer service centers that can meet the ghtest schedules whileachieving the most compe ve pricing through global sourcing.

WE OFFER A FULL RANGEOF HRSG SERVICES

Thermal Performance Modeling To identify causes of performance shortfalls To evaluate benefit of design improvements Modeling is done using Foster Wheelers expert performance

design software which i s continually updated and validatedwith field data

Feasibility and Engineering Studies to Evaluate the Thermal andMechanical Impact of Addition of in-duct burners Turbine changes Capacity increases SCR additions

Site Services Performance, efficiency benchmarking Assessment of water quality issues Investigation of casing issues, hot spots, leaks Burner tuning Investigation of tube corrosion issues Condition, remaining life assessments

Metallurgical Analysis UT testing to determine cracking and tube wall thinning To determine causes of tube failures and develop solutions

Vibration Analysis

To address vibration-related failures in tube assemblies,baffle plates, liner plates

Dynamic Analysis To investigate tube, header, nozzle temperature differential s

and flexibility during start-up, shut-down, and steady-stateoperation

To evaluate life cycle fatigue

HRSG UpgradeUnit & Loca on: Saica 3, Zaragoza,Customer: Saica PaperWork Completed: 2010CC Capacity: 50 MWeGT Model: PG 6581HRSG OEM: Deutsche Babc

FW Scope: Engineering study

Recommended design and opera oimprovements

Supply and erec on and new duct, pand secondary superheaters, a empBMS and safety PLC

Benefts to Customer:

Improved HRSG and plant availabilopera onal exibility and plant per

New HMI for easier plant opera ondiagnos cs

Lowered HRSG gas leakage

HRSG Steam Drum ReplacementUnit & Loca on: Unit 3, BarceloCustomer: ENDESA GENWork Completed: 2011

CC Capacity: 400 MWeGT Model: GT-26HRSG OEM: CMI for Alsto

FW Scope: Replacement of high pressure steam

drum and auxiliary equipment inclengineering, design, supply and ere

Bene ts to Customer: Improved HRSG and plant availab New high pressure drum designed t

eliminate cracking in both circumand nozzle-to-drum welds

Project engineered to minimize HRmodi ca on, site labor and plant d

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AFTERMARKET HRSG SERVICE


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HRSG 032

We offer a full range of steam generator equipment, aftermarket products and services to the power,industrial, and waste-to-energy sectors. Our global manufacturing and engineering network can deliver cuttingedge products and expertise, quickly and cost competitively with best-in-class quality. Established in 1891, ourexperience comes from a heritage of designing, servicing, and continually improving steam generating equipment.

CONTACT US

Steam Generators Circulating Fluid Bed Pulverized Coal Oil & Gas Solar

Bubbling Fluid Bed Package Grate and MSW Metallurgical Waste Heat HRSG

Environmental Products Circulating Fluid Bed Scrubbers Fabric Filters SCR and SNCR Systems Low NOx Combustion Systems

Biomass Combustion Retro ts Coal/Air Control System

Upgrades

Aftermarket Services Condition Assessment Engineered and Replacement

Pressure Parts Weld Overlay and Refractory

Upgrades Replacement Parts Cyclone Burner Retro ts Coal Mill Service and Upgrades Maintenance Services Outage Construction Engineering Studies

Auxiliary Equipment Condensers Feedwater Heater Biomass Gasi ers

Plant Operation Plants owned and

operated by FW Long-term Servic

Agreements

GLOBALL Ywww.fwc.com

CHINAUnit 1 on 6/FRaf es City Beijing Of ce Tower No. 1 Dongzhimen South StreetDongcheng DistrictBeijing, 100007 ChinaT +86 (0) 10 8409 8855

8th & 5th Floor, UC Tower 500 Fushan RoadPudong New AreaShanghai 200122 ChinaT +86 (0) 21 5058 2266

FINLANDMetsnneidonkuja 8Fl-02130 Espoo, FinlandT +358 (0) 10 393 11

Relanderinkatu 2Fl-78201 Varkaus, FinlandT +358 (0) 10 393 11

GERMANYHassenstrasse 5747809 Krefeld, GermanyT +49 (0) 2151 36337-10

Am Zollstock 161381 Friedrichsdorf, GermanyT +49 (0) 6172 26628-0

POLAND Aleja Jana Pawla II 1500-828 Warsaw, PolandT +48 (0) 22 697 6870

ul. Staszica 3141-200 Sosnowiec, PolandT +48 (0) 32 368 1300

SPAINCalle Gabriel Garcia Mrquez, 228230 Las RozasMadrid, SpainT +34 (0) 91 336 2400

SWEDENLindvgen 75602 28 Norrkping, SwedenT +46 (0) 11 285 330

THAILAND 9th Floor, Maneeya Building518/5 Ploenchit RoadLumpini, PathumwanBangkok 10330, ThailandT +66 (0) 2 652 0760

USAPerryville Corporate Park53 Frontage RoadP.O. Box 9000Hampton, New Jersey 08827 USAT +1 (1) 908 730 4000

9780 Mt. Pyramid Court, Suite 260Englewood, Colorado 80112-7060 USAT +1 (1) 303 784 4880

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Heat Recovery Steam Generators Optimized for Any Application