HRSG

TBW Experience List For Heat Recovery Steam Generators With Project Details

B&W

! Turbomach India Pvt. for Welspun, Gujrat.

Thermax Babcock & Wilcox A Division of Thermax Limited

2

2 x 20 TPH, 10.5 Kg/cm g, Saturated, HRSG, Taraus 60 with Supplementary firing, 2004.

! Caterpiller for Appolo Tyres, Gujarat

Boiler & Heater Group D-1, MIDC, R. D. Aga Road, Chinchwad, Pune 411 019. Tel.: +91-20-66126464 Fax: +91-20-27479200, 27479050

2

1 x 11.2 TPH, 22 Kg/cm g, Saturated, HRSG, Taraus 60 unfired, 2004

HRSG installation at Apollo tyres

! Caterpiller for Biocon, Bangalore. 1 x 50.2 TPH, 10.5 Kg/cm2g, Saturated, HRSG, Taraus 60 unfired, 2004

! Reliance Industries Ltd., Hazira 2

2 x125 TPH, 117 Kg/cm g, 512±5 C, HRSG, PG6581 natural gas +, 2004.

! Reliance Industries Ltd., Jamnagar

2

Boiler & Heater Group

Chennai Fatima Akthar Court, 3rd floor, 312 Anna Salai, Teynampet, Chennai 600 018, India. Tel: 91-44-24353831, 24353834, Fax: 91-44-24353841

2 O 1 x 125 TPH, 115 Kg/cm g, 512±5 C, HRSG, Pg6581 natural gas + naphtha, 2004

1 x 11.2 TPH, 10.5 Kg/cm g, Saturated, HRSG, PG6581 natural gas + naphtha, 2004

Mumbai Dhanrajmahal 2nd floor, Chhatrapati Shivaji Maharaj Marg, Near Gateway of India, Colaba, Mumbai 400 039, India. Tel: 91-22-22045391, 22045324, Fax: 91-22-22040859 Delhi 9, Community Centre, Basant Lok, New Delhi 110 057, India. Tel: 91-11-26145319, 26145326, Fax: 91-11-26148679

O

! Caterpiller for Biocon, Bangalore

B&W

Kolkata Azimganj House, 5th Floor, 7 Camac Street, Kolkata 700 017, India. Tel: 91-33-22826711/2/3, Fax: 91-33-22826796

HRSG installation at Aban Power Ltd.

Hyderabad 6-3-649 Nalanda Complex, Somaji Guda, Hyderabad 500 082 India. Tel: 91-40-23310254, 23312013, 23396820 Fax: 91-40-23312335

! Alok Industries Limited, Vapi 2

1 x 30 TPH, 10.5 Kg/cm g, Saturated, HRSG, Taraus 60 unfired, 2006.

www.tbwindia.com

! Reliance Utilities & Power Ltd., Jamnagar

International offices at Bangladesh, Belgium, Brazil, China, Hongkong, Indonesia, Kenya, Malaysia, Nigeria, Philippines, Russia, Saudi Arabia, Sri Lanka, Thailand, UAE, UK, USA

2 O 6 x 315 TPH, 49 Kg/cm g, 396 C, HRSG, Taurus 70, 2006

HRSG installation at Reliance Petrochemical Ltd. ! Gujarat Heavy Chemicals Ltd.,

Gujarat, Vapi 2

1 x 16 TPH, 10.5 Kg/cm g, Saturated, HRSG, Natural Gas, 2006

Thermax Business Portfolio Boilers & Heaters Cooling & Heating Air Pollution Control

We reserve the right to amend any product details without notice.

Nov. 2005 Edition

Captive Power Chemicals Water & Waste Solutions

Heat Recovery Steam Generator Thermal Engineering The International Way

Improving your business is our business

Thermax offers products, systems

and solutions in energy and environment engineering to industrial and commercial establishments around the world. It’s business expertise covers heating, cooling, waste heat recovery, captive power, water treatment & recycling, air pollution control & waste management and performance chemicals. Thermax brings to customers extensive experience in industrial applications and expertise thought technology partnerships and strategic alliance. Operating from it’s Headquarters in Pune (Western India), Thermax has built an international sales & service network spread over South East Asia, Middle East, Africa, Russia, UK and the US. It has a full-fledged ISO 9001 : 2000 and ISO 14000 accredited manufacturing setup. Boiler & Heater Group Thermax's B&H Group provides solutions in Biomass combustion, Waste Heat Recovery and Oil & Gas Fired Boilers to generate steam and power. Thermax also provides Renovation & Modernization solutions for old boilers and heaters.

TBW

TBW Experience List For Heat Recovery Steam Generators With Project Details

The Expertise To Meet Your Needs

! OEP for Oswal Chemicals & Fertilizer Ltd. Shahajahanpur.

TBW's design for HRSGs are based on technology from Babcock & Wilcox, USA who are world leaders with

2 x 100 TPH, 115 Kg/cm2g, 515OC, HRSG on frame 5 gas turbine with gas, 1992.

more than 100 HRSG installations worldwide. These HRSGs incorporate the latest advances in thermal

! Maruti Udyog Ltd., Gurgaon. 1 x 75 TPH, 42 Kg/cm2g, 410OC, HRSG on frame 5 gas turbine with gas, 1992.

technology offering such benefits as multiple pressure levels and unprecedented reliability.

! Essar Gujrat Ltd., Hazira.

TBW can design and supply HRSGs for gas turbines

1 x 50.2 TPH, 42 Kg/cm2g, 410OC, HRSG frame 5 gas turbine, 1993.

ranging from 5MW to 250MW with steam parameters 2

O

up to 500 TPH, design pressure 160 Kg/cm g and 565O C temperature. HRSG installation at Arvind Mills

! Daelim for Numaligarh Refinery Ltd., Numaligarh. 2

O

2 x 130 TPH, 43 Kg/cm g, 456 C, HRSG on frame 6 gas turbine with natural gas and naphtha, 1995.

! Arvind Mills Ltd., Ahmedabad. 2

O

2 x 32 TPH, 44 Kg/cm g, 440 C, HRSG on naphtha, 1996.

! BSES Ltd., Kochi. 2

O

3 x 44 TPH, 46 Kg/cm g, 425 C, HRSG on LM 6000PC, 1998.

! Reliance Petrochemicals Ltd, Jamnagar. 2

O

1 x 125 TPH, 115 Kg/cm g, 510 C, HRSG on frame 6 gas turbine with natural gas and naphtha, 1999.

We supply equipment for various process applications in Petrochemicals, Refineries, Sugar, Power, Steel, Cement, Fertilizer, Paper, Textile etc. We have successfully executed over 1000 units for various applications. Our equipment are installed across the world for various projects in countries like Middle East, South East, CIS, Australia, Europe, Africa through various renowned EPC contractors.

HRSG installation at Oswal Chemicals & Fertilizer

! Tuma Turbomach SA for Sarabhai Piramal Pharmaceutical Ltd., Baroda. 1 x 12.7 TPH, 10 Kg/cm2g, Saturated, HRSG on Centaur 40 turbine with natural gas, 2001.

! Aban Power Ltd., Tamilnadu. 1 x 160/5 TPH, 110/28 Kg/cm2g, 542 HP / 250 MP, Supplementary fired HRSG, 2003.

! Turbomach India Pvt. Ltd. for Deepak Fertilizers, Taloja. 2

HRSG installation at Numaligarh Refinery

O

2 x 22 TPH, 41 Kg/cm g, 350 C, Supplementary fired HRSG with fresh air firing system, 2003.

TBW

The Expertise To Meet Your Needs TBW's design for HRSGs are based on technology from Babcock & Wilcox, USA who are world leaders with more than 100 HRSG installations worldwide. These HRSGs incorporate the latest advances in thermal technology offering such benefits as multiple pressure levels and unprecedented reliability. TBW can design and supply HRSGs for gas turbines ranging from 5MW to 250MW with steam parameters 2

O

up to 500 TPH, design pressure 135 Kg/cm g and 540O C temperature.

Full Scope Capabilities

Quality

l Complete engineering and Design services

l Total Quality Management

l Superior HRSG design programs for predicting

l ISO 9001

accurate performance l Direct satellite link up with B & W main design

facility in USA to check and evaluate HRSG performances l Own state of the art manufacturing facilities in

Pune, India l Impressive track record of strong project

management l In house erection and commissioning expertise l Effective and reliable after sales services l Easy availability of spares l Full fledged R & D facility l Study, retrofit & upgrade of existing HRSG

system

To ensure a superior product at a competitive price and world class quality, TBW brings you benefits of :

l ASME certification for “S” & “U” stamps l Automated manufacturing facilities equipped

with modern machines for critical pressure part fabrication l Modular design to allow for maximum shop

assembly and minimum field erection

Single Drum Construction

Tolerant To Economiser Steaming

Steam drum is located outside the gas path to reduce thermal stresses. This facilitates quicker starts and stops of the HRSG to follow gas turbine operation.

The last rows of economiser are arranged in an upflow configuration. These rows avoid any imbalance in water distribution associated with steaming in the economiser at lower steam loads. Water leaving the economiser enters the baffled portion of the steam drum and passes through cyclone separators to further improve water/steam flow distribution and circulation.

Fully Drainable Superheater

Fully Welded Construction All pressure part tubes are welded to headers allowing for quicker start-ups and shut downs of the HRSG.

Special Drum Internals Specially designed drum internals installed in the steam drum promote circulation and ensure supply of bubble free "Solid" water back to downcomers, maintaining high steam purity (99.99% dry). This results in stable performance during quick load pickups & reduction, which are common operational requirements of HRSGs.

Vertical superheaters can be fully drained, preventing formation of scales on the inside of superheater, which may otherwise lead to higher metal wall temperatures and eventually failure of superheater.

Radiation Screening The first two rows following the burner are constructed of bare tubes arranged in staggered pitching. These two rows screen flame radiation coming from the burner and avoid overheating of fins in subsequent HRSG surface area.

Ease Of Maintenance & Accessibility Access doors are provided in various sections of the HRSG to facilitate inspection and maintenance.

H

Careful Inlet Duct Design Performance of HRSGs is drastically affected by turbine exhaust gas maldistribution. As these gases are highly turbulent, a careful design of Inlet duct, Included Angle of transition ducting and Flow distribution grid is a prerequisite for achieving predicted HRSG performance and preventing overheating of superheater tubes.

LARGE BORE DOWNCOMER HP ATTEMPERATOR HP ECONOMISER-II HP BOILER BANK

HP SUPERHEATER

TBW carries out computer simulation of the gas flow distribution to decide the design of inlet gas ducting, included angle of transition ducting and flow distribution grid.

Gas Tight Internally Insulated Casing The entire HRSG is enclosed in a gas tight casing. Stiffeners are provided to enhance rigidity. This design is based on the concept of "Cold Casing" using ceramic & mineral wool mattresses. Specially designed studs hold ceramic & mineral wool insulation material tightly to the outer casing. The overlapped design of liners covering insulation minimises penetration of flue gases into insulation material. This results in low outer casing temperature minimising thermal expansion of the casing and thermal loads on the GT flange.

H.P. STEAM OUTLET

Safe Location Of Welds Outside The Gas Path All header-to-tube welds are located outside the active gas path thus avoiding direct contact of welds with high velocity, high temperature flue gases. This enhances safety of all pressure parts joints. For Superheaters, header protection is provided to limit metal temperature.

VENT MAKEUP WATER

MP STEAM OUTLET HIGH PRESSURE DRUM

MEDIUM PRESSURE DRUM FROM BFW PUMPS

MP ATTEMPERATOR

FROM BFW PUMPS

INTEGRAL DEAERATOR DRUM

TO BFW PUMPS

MP SUPERHEATER MP BOILER BANK HP ECONOMISER-I DEAERATOR BANK ACCESS DOOR

MAIN STACK

Full Scope Capabilities

Quality

l Complete engineering and Design services

l Total Quality Management

l Superior HRSG design programs for predicting

l ISO 9001

accurate performance l Direct satellite link up with B & W main design

facility in USA to check and evaluate HRSG performances l Own state of the art manufacturing facilities in

Pune, India l Impressive track record of strong project

management l In house erection and commissioning expertise l Effective and reliable after sales services l Easy availability of spares l Full fledged R & D facility l Study, retrofit & upgrade of existing HRSG

system

To ensure a superior product at a competitive price and world class quality, TBW brings you benefits of :

l ASME certification for “S” & “U” stamps l Automated manufacturing facilities equipped

with modern machines for critical pressure part fabrication l Modular design to allow for maximum shop

assembly and minimum field erection

Improving your business is our business

Thermax offers products, systems

and solutions in energy and environment engineering to industrial and commercial establishments around the world. It’s business expertise covers heating, cooling, waste heat recovery, captive power, water treatment & recycling, air pollution control & waste management and performance chemicals. Thermax brings to customers extensive experience in industrial applications and expertise thought technology partnerships and strategic alliance. Operating from it’s Headquarters in Pune (Western India), Thermax has built an international sales & service network spread over South East Asia, Middle East, Africa, Russia, UK and the US. It has a full-fledged ISO 9001 : 2000 and ISO 14000 accredited manufacturing setup. Boiler & Heater Group Thermax's B&H Group provides solutions in Biomass combustion, Waste Heat Recovery and Oil & Gas Fired Boilers to generate steam and power. Thermax also provides Renovation & Modernization solutions for old boilers and heaters.

TBW

TBW Experience List For Heat Recovery Steam Generators With Project Details

The Expertise To Meet Your Needs

! Oswal Chemicals & Fertilizer Ltd., Shahajahanpur.

TBW's design for HRSGs are based on technology from

2 x 100 TPH, 115 Kg/cm2g, 515OC HRSG on GE Frame 5 gas turbine with Supplementary Firing on Natural Gas,1992.

Babcock & Wilcox, USA who are world leaders with more than 100 HRSG installations worldwide. These HRSGs incorporate the latest advances in thermal

! Maruti Udyog Ltd., Gurgaon.

technology offering such benefits as multiple pressure

1 x 75 TPH, 42 Kg/cm2g, 410OC HRSG on GE Frame 5 gas turbine with Supplementary Firing and with Integral Deaerator on Natural Gas, 1992.

levels and unprecedented reliability. TBW can design and supply HRSGs for gas turbines

! Essar Gujarat Ltd., Hazira.

ranging from 5MW to 250MW with steam parameters 2

O

up to 500 TPH, design pressure 160 Kg/cm g and 565 C temperature.

HRSG installation at Arvind Mills

! Daelim for Numaligarh Refinery Ltd., Numaligarh. 2 x 130 TPH, 43 Kg/cm2g, 456OC HRSG on GE Frame 6 gas turbine with Supplementary Firing on Natural Gas and Naphtha,1995.

! Arvind Mills Ltd., Naroda & Santej. 4 x 32 TPH, 44 Kg/cm2g, 440OC HRSG on PGT 10 gas turbine with Supplementary Firing on Naphtha,1996.

! BSES Ltd., Kochi. 3 x 40.2 TPH, 46 Kg/cm2g, 425OC dual pressure unfired HRSG on LM 6000 Gas Turbine, 1998.

HRSG installation at Oswal Chemicals & Fertilizer

! Reliance Petrochemicals Ltd., Jamnagar. 1 x 125 TPH, 115 Kg/cm2g, 510OC HRSG on GE Frame 6 gas turbine with Supplementary Firing on Natural Gas, Naphtha, Kerosene and Distillates,1999.

We supply equipment for various process applications in Petrochemicals, Refineries, Sugar, Power, Steel, Cement, Fertilizer, Paper, Textile etc. We have successfully executed over 1000 units for various applications. Our equipment are installed across the world for various projects in countries like Middle East, South East, CIS, Australia, Europe, Africa through various renowned EPC contractors.

1 x 50.2 TPH, 42 Kg/cm2g, 410OC unfired HRSG on GE Frame 5 gas turbine with Integral Deaerator,1993.

! Tuma Turbomach SA for Sarabhai Piramal Pharmaceutical Ltd., Baroda. 1 x 12.7 TPH, 10 Kg/cm2g, Saturated, HRSG on Centaur 40 turbine with Supplementary Firing on Natural Gas, 2001.

! Aban Power Ltd., Tamilnadu. 1 x 168 TPH, 110 Kg/cm2g, 542OC HRSG on GE Frame 6 FA gas turbine with Supplementary Firing on Natural Gas, 2003.

! Turbomach India Pvt. Ltd. for Deepak Fertilizers, Taloja. 2

O

2 x 22 TPH, 41 Kg/cm g, 350 C HRSG on Taurus 70 with Supplementary/Fresh Air Firing system on Natural Gas & Naphtha, 2003. HRSG installation at Numaligarh Refinery

TBW Experience List For Heat Recovery Steam Generators With Project Details

B&W

! Turbomach India Pvt. for Welspun, Gujarat. 2

1 x 20 TPH, 10.5 Kg/cm g, Saturated, HRSG on Taurus 70 with Supplementary Firing on Natural Gas, 2004.

HRSG installation at Apollo tyres

Thermax Babcock & Wilcox A Division of Thermax Limited Boiler & Heater Group

! Caterpiller for Appolo Tyres, Gujarat

D-1, MIDC, R. D. Aga Road, Chinchwad, Pune 411 019. Tel.: +91-20-66126464 Fax: +91-20-27479200, 27479050

2

1 x 11.7 TPH, 22 Kg/cm g, Saturated unfired HRSG on Taurus 60, 2004

! Caterpiller for Biocon, Bangalore. 2 x 11.2 TPH, 10.5 Kg/cm2g, Saturated unfired HRSG on Taurus 60, 2004

Mumbai Dhanrajmahal 2nd floor, Chhatrapati Shivaji Maharaj Marg, Near Gateway of India, Colaba, Mumbai 400 039, India. Tel: 91-22-22045391, 22045324, Fax: 91-22-22040859

Boiler & Heater Group

Delhi 9, Community Centre, Basant Lok, New Delhi 110 057, India. Tel: 91-11-26145319, 26145326, Fax: 91-11-26148679

! Reliance Industries Ltd., Hazira 2 O 2 x125 TPH, 117 Kg/cm g, 512±5 C, HRSG on GE Frame 6 Gas Turbine with Supplementary Firing on Natural Gas, Naphtha, Kerosene & Distillates, 2004.

Chennai Fatima Akthar Court, 3rd floor, 312 Anna Salai, Teynampet, Chennai 600 018, India. Tel: 91-44-24353831, 24353834, Fax: 91-44-24353841

! Reliance Industries Ltd., Jamnagar 2 O 1 x 125 TPH, 115 Kg/cm g, 512±5 C, HRSG on GE Frame 6 Gas Turbine with Supplementary Firing on Natural Gas, Naphtha, Kerosene & Distillates, 2004.

B&W

Kolkata Azimganj House, 5th Floor, 7 Camac Street, Kolkata 700 017, India. Tel: 91-33-22826711/2/3, Fax: 91-33-22826796

HRSG installation at Aban Power Ltd.

Hyderabad 6-3-649 Nalanda Complex, Somaji Guda, Hyderabad 500 082 India. Tel: 91-40-23310254, 23312013, 23396820 Fax: 91-40-23312335

www.tbwindia.com

! Alok Industries Limited, Vapi

International offices at Bangladesh, Belgium, Brazil, China, Hongkong, Indonesia, Kenya, Malaysia, Nigeria, Philippines, Russia, Saudi Arabia, Sri Lanka, Thailand, UAE, UK, USA

2

1 x 30 TPH, 10.5 Kg/cm g, Saturated HRSG on Taurus 60 with Supplementary firing on Natural Gas, 2006.

! Reliance Utilities & Power Ltd., Jamnagar HRSG installation at Reliance Petrochemical Ltd.

2 O 6 x 315 TPH, 49 Kg/cm g, 396 C, HRSG on Frame 9E with Supplementary Firing on Natural Gas, Naphtha and Distillate, 2006

! Gujarat Heavy Chemicals Ltd., Gujarat, Vapi

Thermax Business Portfolio

2

1 x 16 TPH, 10.5 Kg/cm g, Saturated, HRSG on Taurus 60 Gas Turbine with Supplementary Firing on Natural Gas, 2006

Boilers & Heaters Cooling & Heating Air Pollution Control

We reserve the right to amend any product details without notice.

Nov. 2006 Edition

Captive Power Chemicals Water & Waste Solutions

Heat Recovery Steam Generator Thermal Engineering The International Way