Heat Recovery

Steam Generators
connected excellence in all we do

amecfw.com
 An Amec Foster Wheeler
HRSG producing 70 MWe
of power at the La Rábida
refinery since 2009

1 Heat Recovery Steam Generators

A long history with Heat
Recovery Steam Generators

Since we supplied our first

HRSG to the Rio Pecos
combined cycle plant (Texas,
USA) in 1958, we have
advanced HRSG technology
to a new level of thermal and
mechanical performance,
reliability and ease of
maintenance.

With over 450 Foster Wheeler HRSGs in

the field today with millions of operational For each application, our
hours, Amec Foster Wheeler HRSGs designs are tailored to
have developed a track record of reliable
meet the performance,
operation and high customer satisfaction
for a wide range of combustion turbines. reliability and cost goals
of our customers.
We offer HRSGs for all applications
ranging from large utility combined
cycle power plants to small co-
generation and industrial facilities.

Our client support doesn’t stop once

an Amec Foster Wheeler HRSG is
operational. We provide a broad range of
after-market services to solve problems
and improve performance and reliability
of your HRSG. This applies to not only
Amec Foster Wheeler HRSGs, but to all
HRSGs, no matter the OEM.

Gas turbine experience

u Alstom/ABB u Siemens
u GT-8C, 10, 35 u 
SGT, 600, 800
u General Electric u 
SGT5 - 4000F
u 
PG 6531, 6581, u 
SFT6 - 5000F
7121, 9171 u V64.3, .4
u 
LM 1600, 2500, u V94.2, .3A
6000 u Rolls Royce
u rame 6, 6B, 6F,
F u RB211
6FA, 7, 7B, 7E, 7F, u Westinghouse
7FA, 9, 9E, 9F, u
501D5A
9FA, 9FB u
501F
u Mitsubishi u
251 B6
u 
M501F, FD, SDA
u Solar
u Cemtaur, H
u Mars

Heat Recovery Steam Generators 2

 Amec Foster Wheeler HRSGs are
designed for reliability and long life
Tube support banks for thermal flexibility

Positive casing seal

Positive liner retention system

SCR available on all designs

u

Horizontal and vertical designs
available for both utility and
industrial applications
u

Steam temperatures up to
600°C (1115°F)
u

One, two or three pressure
levels to suit any application
u

Unfired, co-fired and fresh air
fired for guaranteed steam
production even without gas
turbine operation

Flex tube assembly Full penetration tube to header welds Upflow/downflow economizers circuitry

Recent Projects

Algeria York Kimberly Clark de Mexico Ramos Arizpe Facility

Location: Mostaghanem, Algeria Location: Pennsylvania, USA Location: Coahuila, Mexico
Customer: Samsung C&T Corp. Customer: Undisclosed Customer: Iberdola
Start-Up Year: 2019 Start-Up Year: 2017 Start-Up Year: 2016
HRSG Capacity: 4 x 123 MWe HRSG Capacity: 2 x 182 MWe HRSG Capacity: 44 MWe
GT Model: GE 9FA GT Model: 7FA GT Model: LM6000
Fuel: Natural Gas Fuel: Natural Gas Fuel: Natural Gas

3 Heat Recovery Steam Generators

 u

Top supported coils for thermal
mechanical flexibility
u

Harps, C Sections or modular
fabrication for delivery and field
erection flexibility
u

Large sized drain system to
reduce fatigue stress during
rapid start-up and shut-down
u

Extra strength full penetration
welds to handle fast transients
and thermal shocks

Riser manifold

Support system
Riser tubes

Support beam

Roof upper casing

Seal System

Antivibration system

Recent Projects

Hail Power Plant Rabigh II Pocheon

Location: Hail, Saudi Arabia Location: Rabigh, Saudi Arabia Location: Pocheon, South Korea
Customer: Saudi Electricity Company Customer: SCT Customer: Daewoo Engineering & Construction
Start-Up Year: 2016 Start-Up Year: 2016 Start-Up Year: 2016
HRSG Capacity: 4 x 37 MWe HRSG Capacity: 6 x 118 MWe HRSG Capacity: 2 x 148 MWe
GT Model: Siemens SGT-2000 GT Model: SGT6-5000F GT Model: M501J
Fuel: Arabian Light Oil Fuel: Natural Gas & Distillate Oil Fuel: Natural Gas

Heat Recovery Steam Generators 4

Not all HRSG designs are the same

u

Superheaters designed u

Full radial penetration welds u

SCRs are available on all FW
with oversized headers, are used for each transfer HRSGs to achieve very low
downcomers, feeders and tube to header weld so unit NOx emissions
drain systems to reduce can tolerate fast transients u

Designs allow for future
fatigue stress during rapid and thermal shocks with addition of SCR components
start and shut down less risk of weld cracks and when requested
tears associated with lower
quality welds

Recent Projects

Khanom Bugok 3 Stalowa Wola

Location: Amphoe Khanom, Thailand Location: Chungbuk, South Korea Location: Stalowa Wola, Poland
Customer: Mitsubishi Heavy Industries Customer: Siemens AG Customer: Abener
Start-Up Year: 2016 Start-Up Year: 2015 Start-Up Year: 2014
HRSG Capacity: 2 x 158 MWe HRSG Capacity: 133 MWe HRSG Capacity: 160 MWe
GT Model: M701F GT Model: Siemens SGT6-8000H GT Model: GE 9FB
Fuel: Natural Gas & Distillate Oil Fuel: Liquefied Natural Gas Fuel: Natural Gas

5 Heat Recovery Steam Generators

 u

Flexible bellow casing seal
ensures leak-tight connection
while allowing free thermal
expansion through all
operating conditions

u

Counter flow economizer maintains u

Flex tube design provides
water velocities in tubes and efficient inherent mechanical
heat transfer for all operating flexibility ensuring long
conditions HRSG life while enduring
u

Economizer coils are drainable and fast start-ups, upsets and
ventable for fast fill / drain while transients
minimizing steaming during start-up u

Every heat transfer tube
and shut down in every section has at
u

Flow accelerated corrosion eliminated least one tube bend
by use of high chrome tube materials
in critical areas

u

Optimally placed anti vibration
grid plates to minimize noise and
vibration induced by perpendicular
gas flow to tube bundles

Recent Projects

u

HRSG modules hung
from risers manifold with
Emal Qurayyah simplified top supported
Location: Abu Dhabi, UAE Location: Saudi Arabia design to reduce space,
Customer: Samsung C&T Corp. Customer: Samsung C&T Corp. erection time and
Start-Up Year: 2014 Start-Up Year: 2014
manpower
HRSG Capacity: 4 x 133 MWe HRSG Capacity: 12 x 117 MWe
GT Model: GE 9FA GT Model: Siemens SGT6-5000F
Fuel: Natural Gas Fuel: Natural Gas & Diesel Oil

Heat Recovery Steam Generators 6

Our HRSGs are designed for transport
and site erection flexibility

Our capability to supply our HRSGs

in different configurations provides
the most flexibility to our clients,
allowing them to minimize site
erection work and the ultimate
installed cost of their HRSGs.
Our global network of manufacturing facilities
and engineering centers, allows us to provide a
quality product at very competitive cost levels
and delivery times, no matter where the project
is located.

We have world-wide design and fabrication

capability and specialists in systems,
instrumentation, metallurgy and welding
support to our clients.

Recent Projects

Dongducheon Tereftalatos Mexicanos S.A. DE C.V. Top 1002 Pocheon

Location: Kyung-gi-do, Republic of Korea Cogeneration Project Location: Kyung-gi-do, South Korea
Customer: Samsung C&T Corp. Location: Veracruz, Mexico Customer: DAELIM Industrial.Co.,Ltd
Start-Up Year: 2014 Customer: SCS Proyectos, S.A.P.I. de C.V. Start-Up Year: 2013
HRSG Capacity: 4 x 160 MWe Start-Up Year: 2013 HRSG Capacity: 4 x 133 MWe
GT Model: MHI M501J HRSG Capacity: 2 x 49 MWe GT Model: MHI M501G
Fuel: Liquefied Natural Gas GT Model: GE LM6000 Fuel: Natural Gas
Fuel: Natural Gas
7 Heat Recovery Steam Generators
 Harps O-Sections C-Sections Modules

u

Individual tube u

Fully cased tube bundle u

Partially cased u

Individual tube
bundles without for modular assembly tube bundles bundles without
casings or roof u

Most cost effective for u

Most cost effective casing but with roof
u

Most cost effective units one module wide for HRSGs that are u

Most common option
for small HRSGs two modules wide for large combined
cycle HRSGs

Recent Projects

Manifa Cogeneration Norte II Cartagena

Location: Manifa, Saudi Arabia Location: Chilhuahua, Mexico Location: Murcia, Spain
Customer: Tecnicas Reunidas Power Customer: Samsung Engineering Co.,Ltd Customer: Repsol Petroleo S.A.
Start-Up Year: 2012 Start-Up Year: 2012 Start-Up Year: 2011
HRSG Capacity: 2 x 62 MWe HRSG Capacity: 2 x 72 MWe HRSG Capacity: 1 x 15 MWe
GT Model: Mitsubishi M501F GT Model: GE Frame 7FA GT Model: GE PG6581
Fuel: Natural Gas Fuel: Natural Gas Fuel: Natural Gas

Heat Recovery Steam Generators 8

Aftermarket HRSG service

With more than a century of

designing, fabricating, erecting and
starting our own equipment, we
have the experience and capability
to assess your HRSG, recommend
improvements, and predict the
impact on performance, reliability
and operation before any fieldwork
is started.
Service is an integral part of our business.
Preventive condition monitoring, expert
maintenance, rapid response repair work, and
replacement part deliveries are key factors in
achieving maximum plant reliability and cost
effective performance year after year.

Through our service agreements, we

provide comprehensive and cost effective
maintenance programs, ranging from HRSG
inspections to the supply of parts, equipment
and construction services.

Our service is backed by a global network of

manufacturing, engineering and customer
service centers that can meet tight schedules
while achieving the most competitive pricing.

9 Heat Recovery Steam Generators

 UPGRADES

HRSG upgrade
Unit & Location: Saica 3, Zaragoza, Spain
Customer: Saica Paper
Work Completed: 2010
HRSG Capacity: 12 MWe
GT Model: PG 6581
HRSG OEM: Deutsche Babcock

FW scope:
u Engineering study
u 
Recommended design and operational
improvements
u 
Supply and erection and new duct,
primary and secondary superheaters,
attemperator, BMS and safety PLC
u Thermal Performance Modeling
u Benefits to customer:
To identify causes of performance shortfalls
u u 
Improved HRSG and plant availability,
To evaluate benefit of design improvements
operational flexibility and plant
u odeling is done using Amec Foster Wheeler’s expert
M
performance
performance design software which is continually updated u 
New Human Machine Interface system for
and validated with field data easier plant operation and diagnostics
u F
easibility and Engineering Studies to Evaluate the Thermal u Lowered HRSG gas leakage
and Mechanical Impact of
u Addition of in-duct burners
u Turbine changes
u Capacity increases
u SCR additions
u Site Services
u Performance, efficiency benchmarking
u Assessment of water quality issues
u Investigation of casing issues, hot spots, leaks
u Burner tuning
u Investigation of tube corrosion issues
u Condition, remaining life assessments
HRSG steam drum replacement
u Metallurgical Analysis Unit & Location: Unit 3, Barcelona, Spain
u
UT testing to determine cracking and tube wall thinning Customer: ENDESA GENERACION
u
To determine causes of tube failures and develop solutions Work Completed: 2011
HRSG Capacity: 140 MWe
u Vibration Analysis GT Model: GT-26
u o address vibration-related failures in tube assemblies,
T HRSG OEM: CMI for Alstom
baffle plates, liner plates
u Dynamic Analysis FW scope:
u
o investigate tube, header, nozzle temperature u 
Replacement of high pressure steam
T
drum and auxiliary equipment including
differentials and flexibility during start-up, shut-down,
engineering, design, supply and erection
and steady-state operation
u
To evaluate life cycle fatigue Benefits to customer:
u Improved HRSG and plant availability
u 
New high pressure drum designed to
eliminate cracking in both circumferential
and nozzle-to-drum welds
u 
Project engineered to minimize HRSG
modification, site labor and plant down time

Heat Recovery Steam Generators 10

 Amec Foster Wheeler’s Global Power Group
offers a full range of steam generator
equipment, clean air technologies, aftermarket
products and services to the power, industrial,
and waste-to-energy sectors. GPG’s global
engineering, manufacturing, and procurement
network delivers high-quality, cutting-edge
products and services cost competitively, no
matter where the project is located.

products and services

Steam Generators Environmental Products Aftermarket Services Auxiliary Equipment

Circulating Fluid Bed
u  Wet FGD systems
u  u Engineered pressure parts u Condensers

Pulverized Coal
u  CFB scrubbers
u  u Replacement parts u Feedwater heaters

Oil & Gas

u  Dry Sorbent Injection
u  u Weld overlays u Biomass gasifiers

Solar
u  Spray Dry Absorbers
u  u Refractory upgrades

Bubbling Fluid Bed

u  Wet and dry ESPs
u  u Coal mill service and upgrades

Package
u  Fabric filters
u  u Construction Services

Grate and MSW

u  Cartridge collectors
u  u Performance upgrades

Waste Heat
u  Low NOx combustion
u  u Boiler retrofits

HRSG
u  and SCR retrofits

Contact Us
Globally Finland South Korea USA
amecfw.com Metsänneidonkuja 8 7th Floor, 621 Bldg., 76-3, 53 Frontage Rd., PO Box 9000
Fl-02130 Espoo, Finland Samsung-dong, Gangnam-gu, Hampton, NJ 08827 USA
China T +358 (0) 10 393 11 Seoul, Korea 135-871 T +1 908 730 4000
Unit 12 T +82 (0) 2 3446 8325
14th Floor, Tower B Relanderinkatu 2 9780 Mt. Pyramid Ct., Ste. 260
Beijing COFCO Plaza, Fl-78201 Varkaus, Finland Spain Englewood, CO 80112-7060 USA
No.8 Jianguomennei Street, T +358 (0) 10 393 11 Calle Gabriel Garcia Márquez, 2 T +1 303 784 4880
Beijing, China 100005 28230 Las Rozas
T +86 (0) 10 6522 2771 Poland Madrid, Spain 501 Grant Street, Suite 400
ul. Chmielna 85/87 T +34 (0) 91 336 2400 Pittsburgh, PA 15219-442 USA
8th Floor 00-805 Warsaw T +1 412 562 7300
UC Tower T +48 (0) 22 581 00 36 Sweden
500 Fushan Road Lindövägen 75 1080 Holcomb Bridge Road
Pudong New Area ul. Staszica 31 602 28 Norrköping, Sweden Building 100 - Suite 100
Shanghai 200122 China 41-200 Sosnowiec, Poland T +46 (0) 11 285 330 Roswell, GA 30076-4346 USA
T +86 (0) 21 5058 2266 T +48 (0) 32 368 1300 T +1 770 325 7500
Thailand
Saudi Arabia 9th Floor, Maneeya Bldg, Vietnam
PO Box 79311 518/5 Ploenchit Road Suite 706-708, 7th Floor,
Al-Khobar 31952 Lumpini, Pathumwan Central Bldg
T +966 (0) 3 882 2398 Bangkok 10330, Thailand 31 Hai Ba Trung Street
T +66 (0) 2 652 0760 Hanoi, Vietnam
T +84 (0) 4 39393809

Heat Recovery Steam Generators 18Feb15