Step by Step HRSG Rev 02

Step-by-step MANUAL
To Develop a typical Triple Pressure HRSG Boiler

Scheme on Gas turbine with Duct burner
PREPARED FOR:
By
NOVEMBER 2013
Presented by: Project:
3 Pressure HRSG
Step-by-step Manual
List of Contents
1 Construction of the Flue Gas Circuit of the HRSG 4
1.1 Introduction of the heat source 4
1.2 Introduction of diverter damper and bypass stack 6
1.3 Consideration of possible mal flow distribution 7
1.4 Considered Concept of triple pressure HRSG boiler 8
1.5 Introduction of the duct burner 10
1.6 Selection of the fuel for the duct burner 12
1.7 Incorporation of the remaining modules after the duct burner 12
2 Construction of the Water/Steam circuit of the HRSG 15

2.1 Overall Water/Steam Circuit with steam turbine 15
2.1.1 -Boiler Feedwater Inlet 15
2.1.2 -Construction of the overall Water/steam circuit, incl. LP-circuit 16
2.1.3 -Construction of the natural circulation of the LP-system (44) 22
2.1.4 -Construction of the detailed HP-Water Circuit 23
2.1.5 -Construction of the of the HP-DRUM-Evaporator Scheme 24
2.1.6 -Construction of the natural circulation of the HP-system 25
2.1.7 -Construction of the detailed IP-RH Water Circuit 27
2.1.8 -Construction of the of the IP-RH-DRUM-Evaporator Scheme 28
2.1.9 -Construction of the natural circulation of the IP-system 29
3 Integration of the several control loops 30

3.1 Control loop for fuel-supply to ductburner 30
3.2 Control loops in the overall AllData_1.Water Scheme. 31
3.2.1 -Water level control LP-Drum 31
3.2.2 -Control of water inlet-temperature of the Condensate Heater 32
3.2.3 -Control of outlet pressure of the LP-SUPERHEATER 33
3.2.4 -Water Level Control of IP and HP-Drums 33
3.2.5 -Water-Level Control Loop of the IP-RH System Water Scheme 34
3.2.6 -IP-Hot Water Export to external User 35
3.2.7 -Temperature Control Loop Outlet IP-RH1 35
3.2.8 -Remaining control loops of the HP System Water Scheme 36
4 Introduction of Input Data 37

4.1 Input Data Report 37
4.1.1 -Input Flue Gas Data at HRSG Inlet 37
4.1.2 -Input Data HRSG via Report File 39
4.1.3 -Input Data Natural Circulation via Report File 42
4.2 Excel Input Data 43
4.3 Input data for specific components 47
4.3.1 -Steamturbine 47
4.3.2 -Generator 48
4.3.3 -Condensor 49
REVISION : Issued b: Page

20/09/2016 10:50 MPE Step-by-Step HRSG -rev 02.doc 2 of 60
3 Pressure HRSG
Step-by-step Manual
4.3.4 -Booster BFW Pumps 49

4.3.5 -Condensate extraction Pump 49
5 Output Data 50
5.1 Output data report 50
6 Final Outlook of the different Schemes 52

3 Pressure HRSG
Step-by-step Manual
1 Construction of the Flue Gas Circuit of the HRSG

1.1 Introduction of the heat source
(2) The menu “File” offers following options :

♦ “N New “: to create a new boiler structure file
♦ “OOpen”: to open an earlier created and saved boiler structure file
♦ A list of the last 10 recently used boiler structure files which can be
loaded immediately.
(3) Boiler Design ⇒ click on ”OK”

3 Pressure HRSG
Step-by-step Manual
(4) Two screens appear :

♦ AllData_1.FlueGasScheme : to simulate the Flue Gas circuit
♦ AllData_1.WaterScheme : to simulate the Water/Steam circuit
We start normally with the construction of the Flue Gas Circuit, beginning with the Hear
source, i.e. gas turbine exhaust.
(5) Click on the “F

Flue gas side elements” and select the icon “G GasInlet”, (6) drag and
drop the icon into the” FlueGasScheme” screen, select the appropriate icon, within the
proposed options, and double-click on the respective text or click on “O
OK”.
(7) With a right mouse click on the icon a menu will appear and go with the cursor to
option “P
Properties” and change eventually the name “Gasinlet “ into the corresponding
Gas turbine type i.e. GT-M701F
.
IMPORTANT NOTE : don’t forget to give the KED;dbi file a name and to save the file
regularly during the different steps. !

3 Pressure HRSG
Step-by-step Manual
1.2 Introduction of diverter damper and bypass stack
Drag and drop the

respective elements, into
the Flue Gas Scheme,
and select appropriate
icon.

3 Pressure HRSG
Step-by-step Manual
(8) The respective flue gas connections between

elements are established with a right mouse
click on the consecutive elements. A menu
appear, select on top of the menu “Connection
Medium (Gas)” the applicable option, and
make the connection through left mouse click
between the elements.
This operation must be repeated between all

further elements of the HRSG.
1.3 Consideration of possible mal flow distribution
(9) With the flue gas element “S

Streams” all subsequent heat exchangers are divided in
several zones (i.e. 5) and heat transfer calculations in these sections will take into
account the uneven flow or temperature distribution of the flue gas leaving the gas
turbine.
The flow or temperature distribution can be set 100% if considered uniform or

simulated by a function and confirmed by a click on “OK”.

3 Pressure HRSG
Step-by-step Manual
1.4 Considered Concept of triple pressure HRSG boiler

The triple pressure HRSG of this model has following pressure levels at their
respective exit points :
1. High Pressure level : 123 bar(a) at 568°C

2. Intermediate Pressure level : 31,41 bar(a) at 567°C
3. Low Pressure level : 5 bar(a) at 320°C
Based on previous HRSG designs, following arrangement of the different heating

modules in flue gas direction was selected:
• HP - Superheater 1( outlet)
• IP - Reheater 1 (outlet)
• IP - Reheater 2
• Duct Burner
• HP - Superheater 2
• HP - Superheater 3
• IP - Reheater 3
• HP – Superheater 4
• HP – Evaporator
• HP – Economiser 1
• IP – Superheater
• LP – Superheater
• IP – Evaporator
• IP – Economiser
• LP – Evaporator
• Condensate Heater
In this model, with horizontal gas flow, all modules consist of multiple rows with vertical
serrated fin tube, all of the same height.
Following action has to be repeated for each module:
(10) Drag and drop from the ” Heating Surface” menu the “H HSfinnedTubes” – icon and
drag and drop it into the flue gas scheme, select further image “W
WT2” (11) and click on (12)
OK.

3 Pressure HRSG
Step-by-step Manual
With the three first modules, we get following preliminary picture:
(13) : make the flue gas connections between the different modules same as under (8)
(14) : before the duct burner, we have to mix the flue gas streams
Note : With a right mouse click on the icon of the modules, a menu will appear and with
the cursor to option “P
Properties” the standard name “ HSfinnedTubes_xx” can be
changed with the personalized module name “H HP-SH1” etc.

3 Pressure HRSG
Step-by-step Manual
1.5 Introduction of the duct burner
(15) To install the duct burner, select the icon “F Furnace” from the flue gas side
elements, drag and drop it into the flue gas scheme, select the desired icon for a duct
burner and (10) click on “O
OK”.
If other image for the duct burner is preferred, see procedure below and click “OK”
.

3 Pressure HRSG
Step-by-step Manual
When making the connection between the diverter damper and the duct burner (20),
select the standard connection :” Gas with oxygen or Air”.
To change colour and thickness of the connection, place cursor on the connection,
right mouse click to select properties and change width and colour as wanted, and
confirm with click on “OK”
(21) It is useful to provide several test points alongside the flue gas circuit, to check the
in-and/or outlet conditions at certain locations and show exact values of the different
parameters.
(22) As explained under 1.3 a new flue gas element “S Streams” should be included to
divide following modules in several zones and calculate temperature distribution for the
cross-parallel flow arrangements of the respective heating surfaces.

3 Pressure HRSG
Step-by-step Manual
In the studied case, again 5 zones are installed and gas flow and temperature
distribution at 100%, considering a uniform distribution after the first modules and the
duct burner.
Flue gas connection must be made the same way as between previous modules
1.6 Selection of the fuel for the duct burner
From the short-cut to schemes, select ”D

Ductburner Fuel Scheme” and select from the
menu Fuel elements the appropriate fuel nature, i.e. gas.
1.7 Incorporation of the remaining modules after the duct burner

As indicated under 1.4 the next 15 modules are introduced into the flue gas scheme.
This can easily been achieved by placing the cursor on a previous module, with a right
mouse click a menu appears and with the function “ Duplicate” an additional module is
created which can be dragged to its correct location.

3 Pressure HRSG
Step-by-step Manual
This must be repeated as needed to complete the configuration of the HRSG. The
names of the copied modules must be accordingly adjusted (right mouse click on the
module, select properties and change name in first window (23)). Also the necessary
flue gas connections between the modules must be made (24).
REMARK:
The HP-Evaporator consist normally of a larger number of modules, and they are
therefore in this scheme grouped and represented by a gas-group icon in the
AllData_1.FlueGasScheme, which can be opened by clicking with right mouse button
and selecting the option: open group. A new underlying HP Evap.FlueGasScheme is
created where a more detailed construction of the HP-Evaporator can be specified.

3 Pressure HRSG
Step-by-step Manual
The purpose of creating a separate HP-Evaporator scheme is to allow a detailed study

of the heat transfer through the several screens and other specific values.
To complete the flue gas circuit, we have to mix the flue gas streams, a second test
point is added and also a stack. In order to calculate the thermal balance and
efficiency, we have to confirm (25) the first elements or inlet of heat input (1) and the
last elements (L) or outlets of heat considered as losses.

3 Pressure HRSG
Step-by-step Manual
2 Construction of the Water/Steam circuit of the HRSG

We have to build following detailed water/steam schemes
* ModAlldaten_1 water scheme (including LP water system)

* HP water system scheme
* IP-RH water system scheme.
2.1 Overall Water/Steam Circuit with steam turbine
To open the screen for the construction of the water-steam circuit, click on the shortcut
to schemes (26) , select the AllData_1: Water Scheme, and confirm by pressing OK.
The screen for the water circuit will pop up .
2.1.1 Boiler Feedwater Inlet

Select from the water side elements, the icon “F FeedWater”, drag it into the
“A
AllData_1.Water scheme”, select the suitable image and direction (28) and confirm it
by OK.

3 Pressure HRSG
Step-by-step Manual
2.1.2 Construction of the overall Water/steam circuit, incl. LP-circuit

We start with the LP-circuit, fed with cold condensate of 40°C, preheated to 60°C by
recirculating the condensate over the condensate heater, with a three-way control
valve, and further heated before entering in the LP steam drum.
The necessary elements, mixing point, three-way control valve and steam drum are
selected from the Water side elements list, and dragged into the water scheme with
the selected suitable icon.(29)
To complete the LP-circuit, we have to introduce the Condensate Reheater, and the
LP-Superheater, already present in the Flue gas circuit.
(30) Click with mouse right button on the background of AllData_1 Water scheme and
click on Properties of the appearing menu (31). Select the option : “a
add/delete model”
and look for the applicable model, i.e. COND-HTR and LT-SH, click on the model (32)
and shift the selected model in the group by pressing the corresponding arrow-button
(33). When both models are shifted in the group, click OK button (34)

3 Pressure HRSG
Step-by-step Manual
µ

3 Pressure HRSG
Step-by-step Manual
To complete the LP-circuit, put cursor on the BFW-Inlet element, click on right mouse
button, click on “ Connection H2O” and draw the line to the Mix Point (35) selecting
the “S
Standard Connection” and click.
Continue to make the connection to a test point (36) - dragged from the water side
elements, not from the flue gas side elements - continue further to the condensate
heater and from there to the “ 3-way Valve” (37).
From the 3-way control valve, select the “ Connection H2O”, for the main flow and
connect with the Drum.(38)
Between the drum and the LP-SH, we have added from the “P Pressure Drop
Elements” the icon “P PressureDrop” (39), whereby we can introduce an estimated
pressure drop of the LP circuit.
From item (39) we make further the connection with the LP-SH, and from there to an
“E
END” element (40), taken from the Water Side elements.
Note:
• To make every connection, put cursor on the starting icon, click on right mouse
button, click on the corresponding type of connection, bring the cursor to the
ending icon and click on the left mouse button.

3 Pressure HRSG
Step-by-step Manual
• To change thickness or colour of the connection, bring cursor on the line, click on
right mouse button, select Properties and click, change the width, press the
colour button, select the desired colour and press OK.
The moment we introduced the icon “Drum” into a Water scheme, another scheme is
created, i.e. “L
LP-DRUM.EvaporatorScheme” after we have changed the initial Name
“Drum_56” into “LP-DRUM (42).
In this LP-DRUM.EvaporatorScheme we have to introduce the “C CirculationSystem”
(43), to assemble the transferred heat of all respective evaporation surfaces. This must
CirculationSystem_EvaporationScheme”.(44) This is
further been elaborated in the “C
also the case for the IP- and HP pressure systems. (see further)
Remark
• All different created schemes can been seen and called up by pressing on button
(41) “SShortcut to schemes”.
To complete the “Alldaten_1 Water Scheme”, we have to add the HP-system, the IP-
RH-system, the 3-stage steam turbine with generator and the condensor.

3 Pressure HRSG
Step-by-step Manual
At this stage, the entire HP and IP-RH systems are introduced in the scheme with a
single icon “S
SteamGenGroup” (45) from the Water Side Elements, but these systems
need to be further detailed in a separate scheme. These new scheme’s will
automatically been created from the moment that the respective icons are introduced
into the Alldaten_1 Water Scheme.
Further elements introduced from the
“W
Water side Elements” are : 3 Pumps
(46): a IP-Feedwater pump, a HP-
Feedwater pump and a condensate
pump; a three-way valve (47) to divide the
feedwater flow between the IP and HP
system; a mixing point (48) and several
Test points (49)
All these new elements can be renamed with a right
mouse click on the icon, selecting with the cursor in the
appeared menu the option “P Properties” and change
eventually the name as wished.
From the “BBalance Of Plant Elements”, we introduce

two turbine stages with bleed valve (50) and one end
stage (51), the generator (52) and condensor (53).

3 Pressure HRSG
Step-by-step Manual
All these new elements need to be interconnected to complete the circuit.

3 Pressure HRSG
Step-by-step Manual
2.1.3 Construction of the natural circulation of the LP-system (44)
Same procedure to call in the LP-evaporator (54) in the circulation scheme as for the
AllData_1Water circuit. The corresponding down comer pipe and riser (55) are also
inserted with the selected icon. Interconnection H2O are also made.
Don’t forget to set “From LP-Drum” as first model.

3 Pressure HRSG
Step-by-step Manual
2.1.4 Construction of the detailed HP-Water Circuit
From the Shortcut to schemes button, we

call the “H
HP System.Water scheme.”
(56) Click with mouse right button on the background of HP System_Water Scheme
and click on Properties of the appearing menu. Select the option : “a
add/delete model”
and look for the HP-system pressure parts, mainly the economisers and
superheater’s, shift all the respective modes, one by one in the group by pressing the
arrow-button. When all models are shifted in the group, click OK button.
Add further from the water side elements following items : Test point at the inlet , a tap
for spray water injection cooler, the HP drum, the spray cooler, a main steam pipe and
an outlet-element for the HP-system.
Between the drum and HP-SH4, we have added from the “P Pressure Drop Elements”
the icon “P
PressureDrop”, where we can introduce an estimated pressure drop of the
HP circuit.
All above elements need to be interconnected.

3 Pressure HRSG
Step-by-step Manual
Don’t forget to set “HP-System-In” as first model.
2.1.5 Construction of the of the HP-DRUM-Evaporator Scheme
Same procedure as for the LP-DRUM-Evaporator, starting from the shortcut to

schemes (58).

3 Pressure HRSG
Step-by-step Manual
2.1.6 Construction of the natural circulation of the HP-system
(59) Via Shortcut to schemes, we call “H

HP CirculationSystem.Evaporatorscheme.”
(60) With right mouse button on the background of the scheme, click on Properties of
the appearing menu. Select the option : “aadd/delete model” and look for all the HP-
Evaporator elements, shift all the respective modes, in the group by pressing the
arrow-button. When all models are shifted in the group, click OK button.
(61)We further add a number of “water side elements” like dividers, mixers, pipes and
Test-points to complete the natural (or assisted) water circulation system, starting from
the HP-drum with the provided down comers, feeding through the dividers at the
bottom all the evaporator elements, assembling the water-vapour mixtures on top and
returning back to the HP-drum via a number of risers.
The Test-points are used to represent the start-and end connection at the HP-drum,
whereby the start-test-points must be defined as first element.
How all the geometric data of the HRSG are introduced in the simulation will be
explained in a separate chapter, further in this document. A typical piping arrangement
for the natural circulation system is used in our set-up.

3 Pressure HRSG
Step-by-step Manual
Depending on the detailed construction of the HRSG, the interconnecting piping may
be different from this example.

3 Pressure HRSG
Step-by-step Manual
2.1.7 Construction of the detailed IP-RH Water Circuit

Similar as for the HP Water circuit, the Water-scheme for the IP-RH circuit can be
established.
To complete the IP-RH circuit following Water side elements need to be added and
connected, besides the already created pressure parts (62), :

3 Pressure HRSG
Step-by-step Manual
This result in following completed scheme. Item” IP-RH System In” is set as first
element (63)
2.1.8 Construction of the of the IP-RH-DRUM-Evaporator Scheme
Same procedure as before, starting from the shortcut to schemes (64).

3 Pressure HRSG
Step-by-step Manual
2.1.9 Construction of the natural circulation of the IP-system
The scheme for the natural circulation of the IP-system is quite similar to that of the
LP-system, as explained before.

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Step-by-step Manual
3 Integration of the several control loops

3.1 Control loop for fuel-supply to ductburner
In this model, the heat capacity of the duct burner must keep the flue gas temperature
at a constant value, i.e. 600°C at the outlet of the Ductburner. The fuel supply will be
controlled in function of the measured flue gas temperature at test point TP1.
Form the shortcut to schemes we select the “D

Ductburner.Fuel Scheme” and from the
element list we select the Control Elements. The element “F FuelCtrl” is dragged into
the Fuel scheme and connected to the fuel supply with the connection “c
connFuel”.
This control element is further called in the AllData_1FlueGasScheme with the

meanwhile known procedure with right mouse button click on the background 
Properties  add/delete model. The “Ductburner Ctrl” element is in this scheme
connect via “ ConnGasTestPoint” to the Test-Point “TP1” in the flue gas scheme.
To define and activate the control-loop, see next image.

3 Pressure HRSG
Step-by-step Manual
3.2 Control loops in the overall AllData_1.Water Scheme.

3.2.1 Water level control LP-Drum
The control-element is specific for level control, and can only been used for this
function.
Don’t forget to put the control valve in active mode by ticking the white box.

3 Pressure HRSG
Step-by-step Manual
3.2.2 Control of water inlet-temperature of the Condensate Heater
To avoid flue gas condensation in the condensate heater, water temperature should be
above dew point, in our case ≥ 60°C. As the boiler-feedwater (condensate) is about
40°C, temperature at the heater-inlet is lifted to 60°C by recycling a fraction of the
water flow from the outlet of the heater.
The used control valve is a multi-purpose element that can be used to control different
values as :
o Input temperature gas
o Input temperature H20
o Set volume flow
o Set Weight flow
o Set Weight flow gas-side
o Steam content
o Temperature over evaporator temperature ….
In our example we select option “IInput Temp H2O” for this control loop, and fill in 60°C
as set-value for “tt H2O SV”.

3 Pressure HRSG
Step-by-step Manual
3.2.3 Control of outlet pressure of the LP-SUPERHEATER
With double click on the controller, we can fill in the input data. Put the switch for the
controller “o
on” and introduce the set-value for the outlet pressure of the LP-
Superheater.
To visualize the set-values of the controllers, we can drag and drop the value into the
water-scheme, so that we can always check these values during the calculation
process, or modify the set value by a simple double click on the value in the scheme.
3.2.4 Water Level Control of IP and HP-Drums
Both IP and HP systems are fed with saturated water from the LP-Drum, so the test
point connection of the respective pressure controller has to be made in different
System Water schemes.

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Step-by-step Manual
3.2.5 Water-Level Control Loop of the IP-RH System Water Scheme

3 Pressure HRSG
Step-by-step Manual
With the meanwhile known procedure, we add the already created IP-DRUM level
controller and connect the “ ConnDrum” link with the IP-DRUM.
3.2.6 IP-Hot Water Export to external User
The set value for extracted water flow at the outlet of the IP-Economiser, destined for
an external user (i.e. fuel gas heater) can be filled in by double click on the controller.
3.2.7 Temperature Control Loop Outlet IP-RH1

The controller for the IP-Desuperheater has a particular control element which can be
find in the element list.
The set value for the steam temperature at the IP-Reheater Outlet, can be filled by
double click on the controller.
This set-value of the temperature controller, can be visualized by drag and drop the
value into the water-scheme, so that these values always can be checked during the
calculation process, or modified by a simple double click on the value in the scheme.

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Step-by-step Manual
3.2.8 Remaining control loops of the HP System Water Scheme

Similar as for the IP-RH-System, HP-Drum level control and HP-SH temperature has
to be added.

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Step-by-step Manual
4 Introduction of Input Data

4.1 Input Data Report
4.1.1 Input Flue Gas Data at HRSG Inlet
With a double click on the FG-Inlet element, access is opened to the Input/Output File:
• (67) select if further data are mass- or volume related
• (68) introduce Flow, Temperature and pressure
• (69) fill in the elementary flue gas composition, as detailed as possible
• Be sure that sum of all present elements is 100% sharp
Remark: From the Input/Output file you can drag and drop some values into the Flue
Gas Scheme, so that they can easily observed during calculation process.

3 Pressure HRSG
Step-by-step Manual
In-en outlet conditions of media Flue gas, Air, Water and steam at each element can be
easily visualized by a quare box with a group of 4 units : pressure, flow, enthalpy and
temperature.
(70) This can be achieved by drag and drop the respective text (i.e. “Flue gas out”) into the
scheme and selecting the option mass or volume.
Also further specific individual values (e.g. Heat capacity, or O2 concentration) can be
visualized, by dragging and dropping this value into the scheme.
Which values and their size, colour of the names, digits, dimension or background can also
been personalized (see here below).

3 Pressure HRSG
Step-by-step Manual
4.1.2 Input Data HRSG via Report File
Although it is possible to develop a personalized input report file, a more practical way
is to use available report files, developed by others, e.g. “In
nputdata-HRSG.rp”

3 Pressure HRSG
Step-by-step Manual
This Input report file contains 4 windows and several report functions. With the function
: “ Update Report ”, the 4 windows are adjusted with the designed HRSG concept.
Input data can be introduced in the respective listings, and copied in the schemes with
the function :” Write Report in Structure”.
• Window : OveralData
• Window : InflowData (extract)

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Step-by-step Manual
• Window : TubeHeatingSurface
• Window : Controls

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4.1.3 Input Data Natural Circulation via Report File

3 Pressure HRSG
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4.2 Excel Input Data
An alternative and easier way to introduce the input values into the HRSG structure is
via an Excel-file. Once the boiler structure is fixed in the report file, it can be
transferred to an Excel-file via the function “ Transfer Excel”. This excel-file can then
be named and stored. Changes in design during e.g. an optimisation process, can be
inserted in the excel-file and again loaded in the structure the function “ Import from
Excel”. (typical layout see below)
• Excel-sheet : OveralData
Model/Var Value Dimension Description

AllData_1
Construction data : Load 100 % Load of the boiler
Construction data : tRef 25 C Reference temperature
Construction data : sw radiation loss meth Part of energy input(Load) - sw radiation and convection loss method
Construction data : q loss incom comb 0 % heat loss due to incomplete combustion (CO etc )
Construction data : q loss unburned slag 0 % heat loss due to the unburned in the slag
Construction data : TypBoiler insert max. useful heat - Type of boiler for calculation the nominal load;6-Input Qmax
Construction data : Q_Nom 368000 KW Nominal heat power
• Excel-sheet : Controls
Model/Var Value DimensionDescription

LP-P-Ctrl
LP-P-Ctrl : swCtrl on - Control switch: 0 - off, 1 - on
LP-P-Ctrl : p H2O SV 5 bar(a) Set value Water/Steam pressure (func. fr load 0..1)
Rec-Ctrl
ConstrReg3pass : sw_RegPPTO Input Temp_H2O - switch for 3-pass valve control element 0 - T_H2O, 1 - T_Gas, 2- equal press, 3 - Qmediuml)
ConstrReg3pass : swReversed increase - Reversed operation of the controlled valve: =0 heating; = 1cooling
ConstrReg3pass : t gas SV 0 C Set value fluegas temperature (func. fr load 0..1)
ConstrReg3pass : t H2O SV 60 C Set value Water/Steam temperature (func. fr load 0..1)
Ductburner-Ctrl
ConstrRegFuel : swCtrl on - Control switch: 0 - off, 1 - on
ConstrRegFuel : swFuelCtrl t Gas - Fuel control on: 0 - h H2O,1 - t H2O, 2 - W H2O, 3 - h gas, 4 - t gas,5-fuel(W_H2O(load))
FGH-Ctrl
ConstrReg3pass : sw_RegPPTO Set Weightflow - switch for 3-pass valve control element 0 - T_H2O, 1 - T_Gas, 2- equal press, 3 - Qmediuml)
ConstrReg3pass : swReversed increase - Reversed operation of the controlled valve: =0 heating; = 1cooling
ConstrReg3pass : t gas SV 0 C Set value fluegas temperature (func. fr load 0..1)
ConstrReg3pass : t H2O SV 20 C Set value Water/Steam temperature (func. fr load 0..1)
IP-RH-Ctrl
IP-RH-Ctrl : t H2O SV 567 C Set value Water/Steam temperature (func. fr load 0..1)
HP-SH-Ctrl
HP-SH-Ctrl : t H2O SV 568 C Set value Water/Steam temperature (func. fr load 0..1)
• Excel-sheet : Inflow Data

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Step-by-step Manual
Model/Var Value Dimension Description
GT-M701F
Construction : swFlowDim Volume based - Flow dimension: 0 - mass based, 1 - volume based
Construction : press_medium 39,2 mbar Pressure (gauge)
Construction : V_Max 1.836.441 nm^3/h Maximum rate of volumetric flow at standard conditions
Construction : W gas max 2.355,98 t/h Maximum Fuel/fluegas flow
Construction : Temp_Max 604 C Maximum temperature
Construction : N2 74,52 % vol Nitrogen content
Construction : O2 14,37 % vol Oxygen content
Construction : H2O 6,15 % vol Water content
Construction : CO2 4,06 % vol Carbon dioxide content
Construction : SO2 0,00 % vol Sulfer dioxide content
Construction : SO3 0,00 % vol Sulfer trioxide content
Construction : AR 0,90 % vol Argon content
Construction : CO 0,00 % vol Carbon monoxide content
Construction : H2 0,00 % vol Hydrogen content
Construction : He 0,00 % vol Helium content
Construction : NH3 0,00 % vol Ammonia content
Construction : CL2 0,00 % vol Chlorine content
Construction : HCL 0,00 % vol Hydrogen chloride content
Construction : CH4 0,00 % vol Methane content volume
Construction : C2H6 0,00 % vol Ethane content
Construction : C3H8 0,00 % vol Propane content
Construction : C4H10 0,00 % vol Butane content
Construction : TotalComp 100,00 % Total percentage all components
BFW
ConstrInWater : tempMed_matr 105 C Medium temperature
ConstrInWater : W H2O 360 t/h Water/steam flow
ConstrInWater : p H2O 100 bar(a) Water/Steam pressure
Natural Gas
ConstrGas : swFlowDim Volume based - Flow dimension: 0 - mass based, 1 - volume based
ConstrGas : GfuelMax 11,22 t/h Maximum rate of mass flow of fuel
ConstrGas : GfuelMax 14.724,0 nm^3/h Maximum rate of volumen flow of fuel
ConstrGas : LHV 43.397,1 kJ/kg lower heating value
ConstrGas : LHV vol 33.075,3 KJ/nm^3 lower heating value
ConstrGas : t fuel 0,00 C Fuel temperature
ConstrGas : contentCH4 95,00 % CH4 content in flue (stack) gases
ConstrGas : contentC2H6 3,00 % C2H6 content in flue (stack) gases
ConstrGas : C3H8 1,00 % Propane content
ConstrGas : C4H10 0,00 % Butane content
ConstrGas : C5H12 0,00 % Pentane content
ConstrGas : C2H4 0,00 % Ethylene content
ConstrGas : N2 0,00 % Nitrogen content
ConstrGas : CO2 1,00 % Carbon dioxide content
ConstrGas : CO 0,00 % Carbon monoxide content
ConstrGas : H2S 0,00 % Hydrogen sulfide content
ConstrGas : O2 0,00 % Oxygen content
ConstrGas : H2 0,00 % Hydrogen content
ConstrGas : H2O 0,00 % Water content
ConstrGas : AR 0,00 % Argon content
ConstrGas : humidityFGas 0,00 g/kg Humidity of flue gases

3 Pressure HRSG
Step-by-step Manual
• Excel-sheet : TubeHeatingSurfaces
Model HP-SH1 IP-RH1 IP-RH2 HP-SH2 HP-SH3 IP-RH3 HP-SH4 HP-EV1 HP-EV2 HP-EV3
counter flow staggered tubes

bank of
bank of
bank of
bank of
bank of
bank of
bank of
bank of
bank of
bank of
swTubeArr
cross
cross
cross
cross
cross
cross
cross
cross
cross
cross
swFlowType -
ODtube mm 38,1 57,1 57,1 38,1 38,1 57,1 38,1 50,8 50,8 50,8
thkTube mm 4,5 4,5 4 4,5 4,5 4 4 3,6 3,6 3,6
pitchTrans mm 103,2 117,5 117,5 103,2 103,2 117,5 103,2 103,2 103,2 103,2
pitchLong mm 88,9 101,6 101,6 88,9 88,9 101,6 88,9 88,9 88,9 88,9
widthDuct mm 10.650 10.650 10.650 10.650 10.650 10.650 10.650 10.650 10.650 10.650
heightDuct mm 17.680 17.680 17.680 17.680 17.680 17.680 17.650 17.680 17.680 17.680
NumTubesPerRow - 102 90 90 102 102 90 102 102 102 102
NumRows - 3 3 3 3 2 3 2 1 1 1
NumRowsPar - 3 3 3 3 2 3 2 1 1 1
usage factor - 1 1 1 1 1 1 1 1 1 1
Eps_out m^2 K/W 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018
fouling inside m^2 K/W 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018 0,00018
X 10 CrMoVNb 9 1
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
MatTube
-
distTb-W mm 0 0 0 0 0 0 0 0 0 0
angleGas Deg 0 0 0 0 0 0 0 0 0 0
vertical height difference mm 0 0 0 0 0 0 0 17.680 17.680 17.680
length cavity after mm 0 0 0 0 0 0 0 0 0 0
swCalcSurface - yes yes yes yes yes yes yes yes yes yes
A m^2 6.215,6 6.487,8 7.923,3 6.215,6 4.939,2 9.437,6 4.930,8 3.180,1 3.180,1 3.180,1
lengthTube mm 17.680 17.680 17.680 17.680 17.680 17.680 17.650 17.680 17.680 17.680
X 12 CrMo 9 1 Serrated
Serrated
Serrated
Serrated
Serrated
Serrated
Serrated
Serrated
Serrated
Serrated
TypFin
-
MatFin
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
St 35.8
-
pitchFin mm 5,10 6,40 5,10 5,10 4,20 4,20 4,20 4,24 4,24 4,24
heightFin mm 16 16 16 16 16 16 16 16 16 16
thkFin mm 1,2 1,2 1,2 1,2 1,2 1,2 1,2 1,2 1,2 1,2
w_s mm 4 4 4 4 4 4 4 3,97 3,97 3,97
distSegmTube mm 5,08 5,08 5,08 5,08 5,08 5,08 5,08 5,08 5,08 5,08
right hand
right hand
right hand
right hand
left hand
left hand
left hand
left hand
left hand
left hand
(down)
(down)
(down)
(down)
(up)
(up)
(up)
(up)
(up)
(up)
Switch_LR -
NumRows heat trans calc - 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5
numZone - 5 5 5 5 5 5 5 5 5 5
spacing
spacing
spacing
spacing
spacing
spacing
spacing
spacing
spacing
spacing
Fins
Fins
Fins
Fins
Fins
Fins
Fins
Fins
Fins
Fins
swFinSpacing -
Number of fins per length 1/m 196 156 196 196 238 238 238 236 236 236

3 Pressure HRSG
Step-by-step Manual
• Excel-sheet : WUM-Eingabe
vertical height
sw additional
Euler-Faktor
Numbers of
lengthTube
NumTubes
difference
resistance
absRough
id Orifice
thkTube
existing
Radius1
Radius2
Bends1
Bends2
ODtube
Angle1
Angle2
Orifice
ffBend
ffOut
ffIn
Model
mm mm - mm mm - Deg mm - Deg mm - mm - - - - mm -
LP-Downcomer 330 25 2 22000 -21680 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
LP-EVAP 17680 0,35 0,8 0,03 0,2
LP-Riser 300 25 12 5000 4000 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-Downcomer 660 50 2 22000 -21680 1 90 1000 0 90 1000 no 0 0 yes 0,35 0,8 0,03
Nozzle-e 219,1 22 6 2000 500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV13 17680 0,35 0,8 0,03 0,2
Riser-c 330 25 4 5000 3500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV14 17680 0,35 0,8 0,03 0,2
HP-EV15 17680 0,35 0,8 0,03 0,2
HP-dc-1 660 50 2 400 0 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
Nozzle-d 219,1 22 6 2000 500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV10 17680 0,35 0,8 0,03 0,2
Riser-c 330 25 4 5000 3500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV11 17680 0,35 0,8 0,03 0,2
HP-EV12 17680 0,35 0,8 0,03 0,2
HP-dc-2 660 50 2 400 0 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
Nozzle-c 219,1 22 6 2000 500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV7 17680 0,35 0,8 0,03 0,2
Riser-c 330 25 4 5000 3500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV8 17680 0,35 0,8 0,03 0,2
HP-EV9 17680 0,35 0,8 0,03 0,2
HP-dc-3 660 50 2 400 0 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
Nozzle-b 219,1 22 6 2000 500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV4 17680 0,35 0,8 0,03 0,2
Riser-b 330 25 4 5000 3500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV5 17680 0,35 0,8 0,03 0,2
HP-EV6 17680 0,35 0,8 0,03 0,2
HP-dc-4 660 50 2 400 0 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
Nozzle-a 219,1 22 6 2000 500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV1 17680 0,35 0,8 0,03 0,2
Riser-a 330 25 4 5000 3500 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
HP-EV3 17680 0,35 0,8 0,03 0,2
HP-EV2 17680 0,35 0,8 0,03 0,2
HP-MSP 284 20 1 10000 0 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
IP-Downcomer 330 25 2 22000 -21680 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
IP-EVAP 17680 0,35 0,8 0,03 0,2
IP-Riser 120 12 6 5000 4000 0 90 1000 0 90 1000 no 0 0 no 0,35 0,8 0,03
The hydraulic pipe system can be further extended with all interconnecting piping when
the piping lay-out is fixed and exact number of piping connections, number of bends
and other restrictions are finalised.
These input data are not only needed for the natural circulation calculation of the
evaporator systems, but also to calculate exact pressure drop with the interconnecting
piping between economisers, steam drums, evaporators superheater’s and other
equipment in the total water/steam circuit.
To perform the natural circulation, the module “Circulation” the calculation option
“Circulation” must be ticked in the respective box.

3 Pressure HRSG
Step-by-step Manual
4.3 Input data for specific components

4.3.1 Steamturbine
Turbine stage data, like isentropic efficiency and controlled outlet pressure are
preliminary filled in, based on temporarily assumptions or confirmed data from the
turbine manufacturer.
Bleed steam for other users are possible, but not considered in this example.

3 Pressure HRSG
Step-by-step Manual
4.3.2 Generator
Generator efficiency can also be introduced as a combined electrical and mechanical

efficiency,

3 Pressure HRSG
Step-by-step Manual
4.3.3 Condensor
4.3.4 Booster BFW Pumps
4.3.5 Condensate extraction Pump

3 Pressure HRSG
Step-by-step Manual
5 Output Data
5.1 Output data report
Similar as for the input data, the output data can be generated with the report files,
further transferred into excel files. (see chapter 4)The report files can be created
according to personal wishes, or already created out-put files can be used as basis
and modified if needed.

Q
U
A
REVISION
Model
MTD
W gas
DQ_LS
T_Met
outside
h inside
Re_FGas
t medium
t gas inlet
swTubeArr
Presented by:
alfaGasRad
usage factor
alfaGasConv
swFlowType
velocity inlet
20/09/2016 10:50
C t/h KW KW m/s W/m^2 K W/m^2 K W/m^2 K W/m^2 K K m^2 - - - C - C
:
GT-M701F 603,9 2.356,0
Diverter 603,9 2.356,0
MPE
HP-SH1 589,8 2.353,6 10.684,4 22,3 14,86 57,28 0 1.918,10 35,59 48,29 6.215,6 bank of staggered tubes cross counter flow 10.699,6 562,9 1,00 603,9
IP-RH1 580,5 2.353,6 6.953,4 14,5 17,66 60,80 0 811,19 33,01 32,47 6.487,8 bank of staggered tubes cross counter flow 18.688,6 565,8 1,00 589,8
Issued b:
Ductburner 600,0 2.356,1 0,0
HP-EV1 451,5 2.356,1 17.810,5 37,2 16,94 49,72 0 52.328,69 42,10 133,03 3.180,1 bank of staggered tubes cross counter flow 20.378,4 346,9 1,00 475,6
Project:
Step-by-Step HRSG -rev 02.doc

HP-ECO1 318,7 2.356,1 15.874,3 33,2 12,13 55,98 0 12.148,26 44,28 14,10 25.427,7 bank of staggered tubes cross counter flow 20.184,8 317,4 1,00 340,7
IP-SH 316,4 2.356,1 1.634,7 3,4 11,13 46,27 0 775,82 28,56 29,48 1.941,4 bank of staggered tubes cross counter flow 19.418,3 291,0 1,00 318,7
LP-SH 312,0 2.356,1 3.162,9 6,6 10,83 49,94 0 364,32 24,32 85,30 1.524,5 bank of staggered tubes cross counter flow 19.033,5 265,2 1,00 316,4
IP-EVAP 262,1 2.356,1 12.544,6 26,2 9,92 57,84 0 8.230,21 44,25 28,70 9.878,4 bank of staggered tubes cross counter flow 15.148,5 246,6 1,00 280,0
51
IP-ECO 257,1 2.356,1 3.557,1 7,4 9,61 45,04 0 5.769,66 35,44 40,64 2.469,6 bank of staggered tubes cross counter flow 15.377,3 209,0 1,00 262,1
Page
of 60
3 Pressure HRSG
Step-by-step Manual
LP-EVAP 170,0 2.356,1 25.393,7 53,1 9,60 53,11 0 5.306,28 40,70 27,60 22.602,4 bank of staggered tubes cross counter flow 24.314,1 161,7 1,00 206,7
COND-HTR 95,5 2.356,1 51.247,7 107,2 8,89 51,52 0 6.551,26 40,55 24,85 50.855,3 bank of staggered tubes cross counter flow 26.697,9 111,4 1,00 170,0
3 Pressure HRSG
Step-by-step Manual
6 Final Outlook of the different Schemes
The final presentation of the different schemes can be personalized,

A typical example is shown on the next pages.
• General Flue Gas scheme

• General Water-Steam scheme
• Flue Gas scheme HP-Evaporator
• Water-Steam scheme HP-system
• Water-Steam scheme IP-system
• Natural circulation HP-system
• Natural circulation IP-System
• Natural circulation LP-System

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual

3 Pressure HRSG
Step-by-step Manual


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Step by Step HRSG Rev 02

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Step-by-step MANUAL

To Develop a typical Triple Pressure HRSG Boiler

2 Construction of the Water/Steam circuit of the HRSG 15

3 Integration of the several control loops 30

4 Introduction of Input Data 37

REVISION : Issued b: Page

4.3.4 -Booster BFW Pumps 49

6 Final Outlook of the different Schemes 52

REVISION : Issued b: Page

1 Construction of the Flue Gas Circuit of the HRSG

(2) The menu “File” offers following options :

REVISION : Issued b: Page

(4) Two screens appear :

(5) Click on the “F

REVISION : Issued b: Page

1.2 Introduction of diverter damper and bypass stack

Drag and drop the

REVISION : Issued b: Page

(8) The respective flue gas connections between

This operation must be repeated between all

1.3 Consideration of possible mal flow distribution

(9) With the flue gas element “S

The flow or temperature distribution can be set 100% if considered uniform or

REVISION : Issued b: Page

1.4 Considered Concept of triple pressure HRSG boiler

1. High Pressure level : 123 bar(a) at 568°C

Based on previous HRSG designs, following arrangement of the different heating

Following action has to be repeated for each module:

REVISION : Issued b: Page

With the three first modules, we get following preliminary picture:

REVISION : Issued b: Page

1.5 Introduction of the duct burner

REVISION : Issued b: Page

REVISION : Issued b: Page

1.6 Selection of the fuel for the duct burner

From the short-cut to schemes, select ”D

1.7 Incorporation of the remaining modules after the duct burner

REVISION : Issued b: Page

REVISION : Issued b: Page

The purpose of creating a separate HP-Evaporator scheme is to allow a detailed study

REVISION : Issued b: Page

2 Construction of the Water/Steam circuit of the HRSG

* ModAlldaten_1 water scheme (including LP water system)

2.1 Overall Water/Steam Circuit with steam turbine

2.1.1 Boiler Feedwater Inlet

REVISION : Issued b: Page

2.1.2 Construction of the overall Water/steam circuit, incl. LP-circuit

REVISION : Issued b: Page

REVISION : Issued b: Page

REVISION : Issued b: Page

REVISION : Issued b: Page

From the “BBalance Of Plant Elements”, we introduce

REVISION : Issued b: Page

All these new elements need to be interconnected to complete the circuit.

REVISION : Issued b: Page

2.1.3 Construction of the natural circulation of the LP-system (44)

Don’t forget to set “From LP-Drum” as first model.

2.1.4 Construction of the detailed HP-Water Circuit

From the Shortcut to schemes button, we

REVISION : Issued b: Page

Don’t forget to set “HP-System-In” as first model.

2.1.5 Construction of the of the HP-DRUM-Evaporator Scheme

Same procedure as for the LP-DRUM-Evaporator, starting from the shortcut to

REVISION : Issued b: Page