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Insulation Solutions for High Efficiency HRSG Systems
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Transcript of Insulation Solutions for High Efficiency HRSG Systems
Insulation Solutions of Insulation Solutions of High Efficiency HRSG High Efficiency HRSG
SystemsSystems
Presented by:Presented by:Tapas Kumar HaldarTapas Kumar Haldar
Murugappa Morgan Thermal Murugappa Morgan Thermal Ceramics Ltd., ChennaiCeramics Ltd., Chennai
Contents
• Introduction of MMTCL• Our products and Services • Design and installation of insulation
for HRSG – technical• Solution – Cost perspective• References• Benefits• Questions & Answer
Introduction
MMTCL- Key information
• Established in 1983• Joint Venture between Morgan Crucible
Co. plc, UK and Carborundum Universal Ltd. of Murugappa Group
• Manufactures Refractory Ceramic Fiber products
• Plant is located at Ranipet in Tamil Nadu & Ahmedabad, Gujarat
• ISO 9001- 2000 & ISO 14001certified• Market Leader
COMPANY PROFILE
• Morgan Thermal Ceramics- UK£ 1 Billion Global Company Major Business- “Thermal Ceramics”, “Technical Ceramics” & “Carbon”25 Manufacturing Plants of Thermal Ceramics across the worldLeader in Heat Management
“Murugappa” Group- one of the most respected business house in the countryRs.80 Billion Multi-business conglomerateAbrasives, Refractories, Tubes, Bicycles, Fertilizer, Plantation, Financial Services, Sanitary wares
Mission
“To be the most preferred solution provider in high temperature
insulation and passive fireprotection”
Global Presence of Thermal Ceramics
Business definition
• Manufacture and supply energy efficient and productivity enhancing high temperature insulating products
• Provide total package solutions involving own manufactured products and overseas made Thermal Ceramics products
• Provide design, engineering, supervision, and contracting services for turnkey high temperature insulation solutions
• Offer similar comprehensive products, services and solutions to customers requiring PASSIVE FIRE PROTECTION
• Supply asbestos replacement products
Current Facilities
Head office at Chennai
Sales offices at Kolkata, Delhi, Mumbai, Pune
Factories at Ranipet, Tamilnadu &
Ahmedabad, Gujarat
Product Range
Modules
BoardsBlankets
Bulk Fiber
New Generation Products
Pyroblocs
Textiles- Asbestos Replacement
Paper-gaskets, and asbestos replacement Microporous
PYROLOG® & PYOBLOC®
Classification Temp. - 1260 & 1425 Deg C, Density - 160, 190, 240 kg/Cub M
Bulk Density & Thermal Conductivity
Pyrobloc Module
• The lower thermal conductivity of Pyrobloc module compared to Cramic fibre blanket lining system - reduces the heat loss through surface, if the thickness is kept same
• This designer can also reduce thickness of lining with Pyrobloc making the HRSG more compact
Heat Recovery Steam GeneratorsHeat Recovery Steam Generators
Heat Recovery Steam GeneratorsHeat Recovery Steam Generators
• Typically heated by high temperature exhaust from a gas turbine
• Generate steam to drive steam turbine generator or for process purposes
Heat Recovery Steam GeneratorsHeat Recovery Steam Generators
• In the recent years these HRSG units have grown significantly in size.
• As a result, each unit utilizes a significant amount of insulation material
Heat Recovery Steam GeneratorsHeat Recovery Steam Generators
• Unit configuration can be horizontal or vertical (as shown) to provide a compact design
HRSG: DuctworkHRSG: Ductwork
• Typical design consists of insulating layered material (Refractory Ceramic Fibre, Superwool Fibres) sandwiched between an external shell and an internal stainless steel liner
Ductwork with inner liner / shroud using blankets
HRSG: DuctworkHRSG: Ductwork
Purpose of
the shroud is
primarily
for velocity
resistance.
HRSG: DuctworkHRSG: Ductwork
HRSG: Auxiliary BurnersHRSG: Auxiliary Burners
• Typically, the gas turbine exhaust temperatures will be between 550° C and 700° C.
• In order to gain more efficiency , auxiliary burners can be added, increasing the temperatures up to 1000°C.
• In these situation, the liner is pushed beyond its limit. Result is a buckling of the plates.
HRSG: Auxiliary BurnersHRSG: Auxiliary Burners
• The effects are readily apparent and lead to hotspots and eventually failure
HRSG: PyroHRSG: Pyro--Bloc ModulesBloc Modules
• The answer is Pyro-Bloc module.
• Many successful installations have proven the use of Pyro-bloc without the need for an inner steel liner
HRSG: PyroHRSG: Pyro--Bloc Y ModulesBloc Y Modules
• The Pyro-Bloc Y Module system allows for fast installation
• Experienced installers like the flexibility and versatility of this system
HRSG: PyroHRSG: Pyro--Bloc Y ModulesBloc Y Modules
• Pyro-Bloc, being compressible in both directions, easily adapts to irregular spaces and provides an easy on site installation
Pyro-Bloc Module installation on walls of HRSG ductwork showing areas around access door and peep sight
HRSG: PyroHRSG: Pyro--Bloc ModulesBloc Modules
Pyro-Bloc Modules in Diverter Stack, Cogeneration Plant near Calgary, Alberta, Canada
HRSG: PyroHRSG: Pyro--Bloc M ModulesBloc M Modules
• Pyro-Bloc M Modules allow for controlled compression and testing of stud welds.
• Requires pre-laid-out stud installation
HRSG: Increase Velocity Resistance HRSG: Increase Velocity Resistance
• Coatings can be applied to the surface to increase hardness and velocity resistance
• Rigidizer:1800°F (982°C)
• Unikote M 2600°F (1427°C)
Maximum Velocities for Laminar Flow Maximum Velocities for Laminar Flow Across the Surface of Ceramic FiberAcross the Surface of Ceramic Fiber
ProductsProducts M/secM/sec Ft/secFt/sec
• Stacked Blanket 15-21 50-70• Pyro-Bloc, 128kg/m3 (8#) 30 100• Pyro-Bloc, 160kg/m3 (10#) 37 120• Pyro-Bloc, 192kg/m3 (12#) 45 150• Pyro-Bloc, 240kg/m3 (15#) 45 150• Pyrobloc + Unikote 53 175
HRSG: Cost Comparison HRSG: Cost Comparison -- PyroblocPyrobloc
Typical Pyro-Bloc vs Blanket with liner plate: Price Comparison per sq mtr
System Item Price (Rs) Remarks
Pyro-Bloc
Cera Pyrobloc Module, Size- 305*305*400mmT,
Grade - 1260 DegC, Density - 192 kg/m3
16,500 11 pce/sq.mtr with SS anchor
Back up Cerablanket, 25 x 610 x 7300 mm, 128 kg/m3 250 Cost per balnket Rs. 1000/roll
System Installation Cost 2,500 Rs. 2500 per Sq. mtr.
Total Cost 19,250
HRSG: Cost Comparison HRSG: Cost Comparison -- BlanketBlanket
Typical Pyro-Bloc vs Blanket with liner plate: Price Comparison per sq mtr
Blanket
Ceramic Fibre Blanket, 25 x 610 x 7300 mm,
Density -128 kg/m3 (3.9 rolls/m2 for 425
mm thk lining )
3,900 Cost of 16 layers per sq. mtr @
Rs. 1000/roll
Shroud Stainless Steel Liner & Anchor etc 12,760
2.75 mm thk SS 310 plate @ Rs. 580/kg + Stud & nut & washer
@ 75/set, 16 sets/m2
System Subassembly & Installation 1,500
Fabrication Charge Rs. 250/m2 + Shearing Charge Rs. 6/kg + Site installation Rs. 250/m2
128kg/m3 Total Cost 18,160
HRSG: Installation ReferencesHRSG: Installation References
• > 300 HRSGs lined Globally with Thermal Ceramics Materials
• Around 80 installations are lined with Pyrobloc Modules worldwide: A non-shrouded lining systems
HRSG: Installation References HRSG: Installation References -- IndiaIndia
• Reliance Industries – Revamping of four HRSG
• Nagarjuna Fertilisers & Chemicals -Revamping of one HRSG
• Thermax – Five new HRSGs under installation at Reliance
• Larsen & Toubro – Commenced supplies for five new HRSGs at IOCL Panipat
HRSG lining with Pyrobloc: BenefitsHRSG lining with Pyrobloc: Benefits
• Gives viable options to designer and user in designing high efficiency duct fired HRSG
• Fast installation and reduced project execution period
• Enhances heat recovery by lowering heat loss- more steam and higher power output
• Reduces unplanned shutdowns, enhances plant availability
• Reduces maintenance costs
Thank you