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