Heat RecoveRy

Steam GeneRatoRS
for combined-cycle
power plants

Our world has an ever-growing appetite for energy

balanced by an increasing concern for the
environment. Alstom delivers the clean power
and clear solutions that power producers
and industries need to meet these increasing
challenges.
As a world leader in providing Heat Recovery
Steam Generators (HRSGs) for combined-cycle
power plants, Alstom helps power operators
balance the difficult challenges of lowering output
costs while reducing emission.
For more than 75 years, Alstom has established
a track record of quality, safety and responsiveness
to versatile market needs. Alstoms more than
1,500 gas power plant experts are committed
to meet any gas power plant operators need
whether it is designing and installing a plant from
the ground up or retrofitting an existing facility.

75
750
1,500

Key facts

years of innovation
HRSGs installed wordwide
gas R&D professionals

With more than 750 HRSGs

installed worldwide, Alstom is a
world leader in supplying HRSG
behind all major OEMs gas turbines.

Advanced technology for your

combined-cycle power plant
Industry-leading expertise

Alstom has decades of experience in developing and installing

HRSGs for combined-cycle and co-generation plants. Our
in-house design, manufacturing and R&D make us one of
the largest HRSG suppliers in the world. We are proud to say
that leading power producers around the globe prefer our
HRSG for demanding applications and a wide variety of plant
operating regimes.

Operational flexibility

Unique Optimised for Cycling and Constructability (OCC)

design provides unparalleled flexibility needed for reliable
high-cycling duty. Alstom HRSGs are capable of fast starts,
high ramp rates and high turndown resulting in enhanced
flexibility under a wide range of operational scenarios.

Reliability and maintainability

Decades of experience have gone into the design of our HRSGs.

This has ensured not only a reliable design that reduces
maintenance and inspection but also a design that enables
optimal access to critical areas of pressure parts.

Emissions reduction

Increased concerns for environment are driving power plants

to minimise their environmental footprint. Alstom offers proven
solutions for CO, VOC and NOx emissions reduction and control
technologies for full and part load operation.

Advanced engineering

Alstoms HRSG design has been validated and proven over

decades in hundreds of successful operating units. Alstom
is committed to improving our designs to match evolutions
in gas turbine technology while ensuring high reliability
and availability. We continue to improve designs by learning
from our past experiences. We utilise state-of-the-art systems
for parametric modelling resulting in a high quality product.

Quality

We manufacture pressure part modules in-house at the

Alstom manufacturing facilities in Europe and Asia. All HRSGs
components are manufactured according to our stringent
quality control systems resulting in a superior product meeting
the most demanding project requirements and delivery
schedules.

03

Clean Power,

NE
L OWE R
I
ENVIRO N G
NM
FO OT P R EN
I N T TAL

TA
L

GE

EN

ONM
ENVIR

CLEAN

TIONS
PERA
E O

CO

BL

G
IN
AS LITY ITY
L
BI ABI

Our Power generation

offering is based on a
deep understanding of
power markets and our
customers needs. It is
organised around three
levers to maximise the
return of assets over
their entire lifecycle.

TY

IN
FL CR
& EX E
RE I
LI

RE

EN

D E E R GY
P E SE

ON

RI

AT

DA

IT

SP

SI

L
BI

CU

ON

How Alstom is helping you

G
IN
C
U
RED T OF
CO S CITY
RI
ELECT

PE

TITI

AFF

V E A S S E T SY
CIT

ORDAB

L E EL E CT RI

REDUCING
COST OF ELECTRICITY

LOWERING
ENVIRONMENTAL FOOTPRINT

INCREASING
FLEXIBILITY & RELIABILITY

It takes competitive assets to keep

electricity affordable. We enable power
companies to compete successfully in
the marketplace and provide affordable
electricity to consumers. We help you
reduce the cost of electricity through:

Clean generation is one way of

demonstrating environmental
responsibility. Another is lowering
resource usage, visual impact and noise
pollution. In both cases, we can help
you meet or exceed regulations and
environmental standards. That is why
Alstom innovates in the following areas:

Intermittent power generation is a

growing challenge of energy security, as
is maintaining an aging installed base
and adapting it to changing market
conditions. We help you tackle both
issues so that you can enjoy dependable
operations with:

Efficiency improvements
CAPEX reduction / scaling up
Capacity Factor increase (renewable)
Lead time reduction
Competitive O&M
Competitive financing

04

Renewable portfolio
Natural resource optimisation
Pollutants control
(SOx, NOx, PM, mercury)
CO2 emission reduction & CCS
Land use, visual impact and noise
Water intensity reduction &
recyclability

Maintainability and outage

time reduction
Operational and fuel flexibility
Designs and service for improved
availability and reliability
Climate packages
Energy storage

Clear Solutions

meet the challenges of energy sustainability

Keppel I KA13E2-2 power plant, Singapore

Our commitment to customers

Fuel prices and availability fluctuate more than ever and
environmental concerns continue to make headlines.

As one of the largest power generation solution providers in

the market, Alstoms gas clean technologies have kept pace
with power producers dynamically changing needs for increased
production at lower cost and with lower environmental impact.

REDUCING
COST OF ELECTRICITY

LOWERING
ENVIRONMENTAL FOOTPRINT

up to +50%

>30%

output without additional

fuel consumption

reduced emissions
per MWh produced

INCREASING
FLEXIBILITY & RELIABILITY

Alstoms HRSGs can be configured

and optimised for any type of gas
turbine and steam cycle

05

Optimised

Any configuration.
As a leading supplier at a global level, we have a comprehensive portfolio of HRSGs for both 50 Hz and 60 Hz markets.
Alstom HRSGs can be offered as a standalone component optimised for any type of gas turbine and steam cycle. It is also
offered as a steam tail integrated with an Alstom steam turbine.

Optimised for Cycling and Constructability (OCC)

Cycling

A high-cycling plant is critical to balance demand and everchanging supply from renewables. Alstoms unique OCC
HRSG design uses single-row harps with smaller diameter
headers resulting in lower stresses and faster start-up times.
Alstoms innovative drum and SH outlet manifold design
permits high cycling and operational flexibility.

Cost-effective construction

Alstom is a world leader in cost-effective HRSGs from both

design and constructability standpoints. Our OCC design
maximises the use of our unique shop-assembled modular
designs resulting in fewer heavy component lifts and fewer field
welds. Alstom utilises reference designs to minimise costs while
tailoring each unit to meet project performance and site-specific
requirements. All of this results in a reduced field erection cost
providing a truly cost-effective solution.

Cutting edge design

Stress analysis of single-row versus multi-row design confirms
smaller diameter, single-row harps provide three times less
stress than the industry standard conventional multi-row
harps with bent tubes and large diameter, thick walled headers.

Single-row harp design

06

Conventional multi-row harp design

HRSG solutions

Anywhere in the world.

Comprehensive range of products and solutions

Combined-cycle power plants

Alstoms HRSG can be configured and optimised for any type

of gas turbine and steam cycle. Ideal for high-cycling plants
experiencing daily starts and stops, our HRSGs provide:
Optimised hot and cold end performance for maximised
efficiency
High thermal flexibility for fast start-up
Variety of modular options available for the optimum solution

Steam tail and add-on projects

Alstom offers HRSGs as part of a steam add-on to convert

a simple-cycle to combined-cycle increasing power output
and efficiency with no additional fuel consumption. We also
offer steam tail with optimised HRSG and steam turbine
generators enhancing performance, start-up times and wrapped
performance guarantees.

HRSG experience GT range

Gas turbine size

For a wide range of gas turbines

We have built HRSGs for leading international power
companies across the world including over 300 for plants with
gas turbines rated greater than 150 MW. With our portfolio
including horizontal and vertical drum types, we can provide
HRSGs for conventional class (E-Class), advanced class
(F-Class) and very large class (G/H/J-Class) gas turbines.

>150 MW
50 to 150 MW
0

100

200

300

400

Number of HRSG supplied

Alstom continues to set industry benchmarks for operational

flexibility and constructability. Our HRSGs were the first to
feature single-row harps and we achieved a milestone by shipping
two fully assembled F-Class HRSGs into New York City in 2005.
07

Superior design
Meeting

CAPTION_WHITE_lore_ipsum_(Optional)

Horizontal drum
type OCC
Horizontal drum type HRSG features vertical tube, natural
circulation design with horizontal gas flow. HRSGs can be
customised as single, dual or triple pressure with or without
reheat. Design features on the OCC HRSG have been refined
over decades based on cutting-edge R&D and field experience.
The HRSG is available in various configurations to ensure the
overall project cost and schedule is minimised. Four modular
options include harp bundle design, module design, C-frame
design and fully assembled single piece HRSGs.

Vertical drum type

Vertical HRSG design features horizontal tube, with vertical
gas flow optimised for steam tail add-on applications where
space is at a premium. Alstoms vertical HRSG features a
natural circulation design that can accommodate heavy fuel oil
operation. We have nearly 300 vertical HRSGs around the world
including almost 40 with 150 MW gas turbines and above.

08

HRSG scope features

HRSG lifetime monitoring system (AMODIS)
Optimised plant operation
Reduced lifetime consumption

Supplemental firing system

Reliable peaking power
Increased operational flexibility

SCR and CO catalyst

Reduced NO , CO and VOC emissions

Low environmental impact
x

Noise reduction
Acoustic enclosure
Stack silencer
Vent and safety valve silencers

and construction

objectives

Based on proven designs we tailor our

HRSGs to meet our customers needs.

HRSG design features

Single-row harps
Small diameter headers
Reduced thermal stresses allow high cycling
and faster start-up times
Enhanced drain arrangement
Minimised Flow Assisted Corrosion (FAC)

Innovative drum and superheater

outlet manifold design
Drum contoured nozzles
High strength materials
Enhanced manifold design

Compact inlet duct

Improved flow distribution
Reduced pressure drop
Accommodates overhead pipe rack

Fully ventable economiser

Eliminates vapour lock

Minimised FAC
Use of low alloy in strategic areas
Piping design with limited flow velocities
in single and two phase regions

HRSG Triple pressure reheat design with supplementary

firing and emission control equipment for CO, VOC and NOx

09

Working in
Innovation and

CAPTION_WHITE_lore_ipsum_(Optional)

HRSG global footprint

Alstoms worldwide footprint includes three execution centres, two manufacturing centres and a global supply chain. This gives
us the flexibility that our customers value. We have delivered and installed more than 750 HRSGs across the world, and we have
acquired a broad industry expertise that enables us support the customers in an efficient and responsive manner.

Front office
Project execution centre
Manufacturing centre
R&D centre

Baden (Switzerland)
Global front office

Delhi (India)
Project execution centre

Surabaya (Indonesia)
Manufacturing centre
Project execution centre
Windsor (USA)
Project execution centre
R&D centre
Dubai (UAE)
Front office

*The facility opening is planned for 2015.

10

Setubal (Portugal)
Manufacturing centre

Jeddah (KSA)
50/50 JV Alstom/Bemco
Manufacturing centre*

partnership
customer focus

Joint Venture set up with Arabian Bemco to establish a new

manufacturing facility for the growing market in the Middle East.
The world-class facility near Jeddah in the Kingdom of Saudi
Arabia (KSA) will focus on supplying HRSGs to Saudi Arabia and
the wider Middle East market.

Research and development Global service

Alstom Power employs 4,000 people worldwide in engineering
and 1,500 in R&D. We also work with 30 of the best universities
around the globe on cutting-edge research. All our research
is motivated by our desire to find the best solutions for our
customers. We focus on innovative technologies for all stages of
our products life cycle.
Alstom is one of the few HRSG suppliers that have the support
of a diverse R&D community consisting of scientists and
engineers with diverse range of expertise from heat transfer,
fluid dynamics, combustion, metallurgy and water chemistry.
Alstom has state-of-the-art computational fluid dynamics
lab, finite element analysis, transient modelling, lifetime
assessment. Alstom supports various ASME and EN code
committees, industry research and standard organisations such
as Electric Power Research Institute (EPRI) and National Fire
Protection Agency (NFPA).

With a network of over 60 local service centers around the

world, Alstom has the portfolio to support you with all aspects
of HRSG maintenance throughout the life of the plant. We
also provide a full range of maintenance and customer service
solutions.
The portfolio of services includes:
Parts and products
Pressure parts and assembly
Fabricated products including dampers, access doors,
replacement ducts etc.
Valves, desuperheaters, instrumentation

Field services
Inspection and condition assessments
Repair and outage support
On-site testing and recommissioning
Outage planning and support

Advice and operational support

Operational flexibility assessment

Design life studies
Engineering studies
Performance improvements

Improved operational flexibility

Upgraded piping and pressure parts
Component improvements

11

Global footprint
Alstoms HRSGs

WILDCAT POINT (USA)

In 2014, Alstom has been awarded a steam tail package for Old
Dominion Electric Cooperatives Wildcat Point combined-cycle
power plant in Cecil county, Maryland. The plant will generate
approximately 1,000 MW, enough to power 390,000 homes. The
plant is scheduled for commissioning in mid-2017.
Alstom will provide two OCC module triple pressure reheat
horizontal drum type HRSGs designed for cycling and constructability.
Alstoms OCC module is designed such that it can be transported
by sea, rail or truck depending on the site location while providing
a high level of modularisation. The scope for the HRSG includes
supplemental firing and emissions control equipment for NOx, CO
and VOC emissions.

NORTH BANGKOK 2 (THAILAND)

2KA26-1 single-shaft 850 MW power plant in consortium with

Sumitomo Corporation in Nonthaburi province.
Under this project, Alstom Surabaya Execution Centre (SEC) provides
two units horizontal, natural circulation, triple pressure with reheat,
double wide, top supported, HL-51 type, HRSGs supplied to site in
harp bundles (like Tuas concept), located downstream of a GT26 gas
turbine for use in a combined-cycle power plant. The steam produced
by one HRSG is used to drive one steam turbine generator set.

Project highlights worldwide

Alstom has decades of experience in developing and installing HRSGs for
combined-cycle and co-generation plants behind all major gas turbines.

AL-ANBAR (IRAQ)

RIYADH PP12 (SAUDI ARABIA)

The HRSGs into consideration are horizontal, drum-type, OCC

bundle design, triple pressure, reheat and un-fired type. The HRSGs
will be designed and manufactured as per ASME with code stamp.

This is the first break-through HRSG order for Alstom in Saudi Arabia.
Once completed, the plant located 140 km west of the Saudi capital
will produce a net output of 1,992 MW at high temperatures with
high efficiency.

First break-through HRSG order for Alstom in Iraq

In 2013, Alstom was awarded a contract to provide power generation
equipment (4GT26, 4 HRSGs, 2steam turbines, 6generators)
for the 1,642 MW Al-Anbar gas-fired combined-cycle power plant
being built 150 km to the west of Baghdad in Iraq.

Alstoms first steam tail in the Kingdom of Saudi Arabia with

equipment offered in a novel integrated package.
Alstom was awarded in 2012 a contract to supply two steam tails
to the new Riyadh PP12 gas-fired power plant. Under the scope of the
contract, Alstom will deliver 8 HRSG, 2STF30C and 2generators.

The HRSGs are horizontal, drum-type, OCC module design, triple

pressure, reheat and un-fired type, designed and manufactured as
per ASME with code stamp.

12

and project highlights

in action

Fujairah 2 (UAE)

Co-generation for desalination

In 2007 Alstom was awarded a full turnkey EPC contract for the
largest newly constructed independent water and power project in
the UAE.
Based on GT26 gas turbine, this 2,000 MW and 130 MIGD hybrid
desalination plant used multi-effect reverse osmosis technologies
to become one of the best performing power plants in the world
proving highly efficient in minimising both gas consumption and
CO2 emissions.
Alstom provided five dual pressure OCC harp bundle horizontal
drum type HRSGs designed for high cycling and constructability.
Each HRSG is equipped with a dual fuel supplementary firing system
capable of firing 245MW thermal while maintaining low NOx and
CO emissions.

Keppel (Singapore)

Flexible and efficient solution

In 2010, Alstom was awarded a full EPC contract to build and
maintain a new 2400 MW power plant in Singapore for Keppel
Merlimau Cogen (KMC) Pte Ltd. Keppel II will be built next to
the existing KA13E2-2 Keppel I in the Tembusu sector of Jurong
Island. Alstom also built the initial 500 MW power plant and is now
delivering an 18-year operation and maintenance contract.
Alstom will provide two OCC module triple pressure reheat
horizontal drum type HRSGs designed for high cycling and
constructability. Alstoms OCC module is designed such that it can
be transported by sea, rail or truck depending on the site location
while providing a high level of modularisation. Keppel II HRSG is
designed and manufactured per ASME and meets local codes and
standards.

Cycofos (France)

Fast, innovative integrated power solution

Located in Fos-sur-Mer in Southern France, this Alstom project was
composed of two power plants: a 420 MW gas-fired combinedcycle power plant based on the GT26 turbine and a 60 MW steam
power plant. Alstom developed an integrated power solution to meet
CyCoFos requirements of having two different power plants using
different fuels and supplying energy in a short time frame.
Alstom supplied one triple pressure with reheat OCC C-Frame drum
type HRSGs. Alstom C-Frame design greatly reduced the field labour
needed to install the HRSG pressure parts and casing leading to
shorter lead times to produce electricity. The HRSG was designed to
meet ASME PED and local codes and standards.

Astoria (USA)

An innovative solution
Alstom was awarded a contract for two triple pressure with reheat
OCC horizontal drum-type fully assembled HRSGs for the Astoria
Is project in 2005. Astoria I HRSGs are behind GE 7FA gas turbines
and are a part of the 500 MW combined-cycle power plant located
in Queens, New York, USA and owned by Astoria Energy II LLC.
The scope for the HRSG included supplemental firing equipment
and emission control equipment for NOx, CO and VOC emissions.
With this project, Alstom has taken modularisation to the next level.
Astoria I HRSGs were fully assembled in Indonesia and delivered to
the Astoria project site, with each HRSG being 36 metres high and
weighing 2,600 tonnes. Each HRSG was delivered fully fitted out with
platforms, valves, piping, insulation and electrical equipment.
Alstom was awarded a follow up project for two additional HRSGs
for Astoria II in 2008. The Astoria I and II projects reinforce Alstoms
leading position as a provider of cost-effective HRSGs from both
design and constructability.

13

Partnership throughout

the plants lifecycle

Forward thinking services

In todays dynamic markets, the traditional concept of base load production is increasingly challenged by the influx of
intermittent sources. Price competition and stringent emissions regulations make the need for flexible operations
greater than ever. Therefore, plant owners and operators look for partners who are willing and able to develop flexible
solutions that will increase production efficiency and reduce emissions throughout the whole lifetime of their equipment.

In combined-cycle power plants or industrial co-generation

plants, the Heat Recovery Steam Generator (HRSG) makes a
vital contribution to total plant efficiency. But as a large metal
structure exposed to wide temperature fluctuations, the HRSG
needs proactive attention to ensure continued reliability as
operational modes become more dynamic. From optimising
operations or upgrades for power and flexibility, Alstom has
the expertise and the implementation capabilities that only a
global OEM and field service provider can deliver.

Presence

With operations in more than 70 countries, Alstom is close to

customers all over the world. Thanks to our teams of trained
and certified HRSG field specialists, you are assured of service
excellence and rapid responses at all times. Building on our
historical HRSG competence centres and OEM construction
capabilities we now have a powerful and cost-effective global
presence.
62 local service centres serving 70 countries
12 locations with HRSG field service resources
2 global HRSG service engineering centres

Facts & figures

14

Solutions

The HRSG system plays a crucial role in the overall performance

of a power plant. That is why Alstom offers a one-stop
shop with a full portfolio of solutions for this valuable but often
underestimated asset.
Alstom solutions cover the whole HRSG lifecycle and include:
Technical expertise and operational support
Field service, parts and repairs
Life extension and performance improvement

Technology

Thanks to our OEM expertise and service-focused R&D,

Alstom has a number of technology-driven solutions for
HRSG operations, maintenance, outage management
and lifecycle optimisation. Our key technologies focus on:
Life assessment from code calculation to
detailed finite element analysis
Performance modelling
Numerical or physical flow modelling
Structural design pipework or structures
Metallurgical analysis
Water and steam cycle chemistry

>100 years boiler-building experience

>50 HRSG inspections per year
>50 trained HRSG inspectors
>260 project and design engineers
>62 local service centres

Alstom
Alstom is a global leader in the world of power generation,
power transmission and rail infrastructure and sets the benchmark
for innovative and environmentally friendly technologies.

Power generation

Alstom builds the fastest train and the highest capacity automated
metro in the world, provides turnkey integrated power plant
solutions and associated services for a wide variety of energy
sources, including hydro, nuclear, gas, coal, wind, solar thermal,
geothermal and ocean energies. Alstom offers a wide range of
solutions for power transmission, with a focus on smart grids.

Power generation
Alstom Power offers solutions which allow their customers to
generate reliable, competitive and eco-friendly power.

Electrical grid

Alstom has the industrys most comprehensive portfolio of thermal

technologies coal, gas, oil and nuclear and holds leading positions
in turnkey power plants, power generation services and air quality
control systems. It is also a pioneer in carbon capture technologies.
Alstom offers the most comprehensive range of renewable power
generation solutions today: hydro power, wind power, geothermal,
biomass and solar. With ocean energies, we are developing solutions
for tomorrow. Alstom is one of the world leaders in hydro power,
the largest source of renewable energy on the planet.

Rail transport

Printed on environmentally friendly paper. A PDF version of this brochure is available at: www.alstom.com

TPWR/PROSOL/HRSGCCPP/EN/9.2014/CHE/2378 ALSTOM 2014. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or
should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is
subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Photo credits: ALSTOM 2014. All rights reserved.

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Switzerland

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