HRSG Core Topics Student Manual PDF

HRSG Core Topics
This document is intended for use only by employees of ALSTOM Power, Inc.
All information herein is considered strictly confidential. This document is
supplied with the understanding that it will be held confidentially and will not be
disclosed or offered to third parties without prior written consent of ALSTOM
Power, Inc.
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TABLE OF CONTENTS
Preface ................................................................................................................... vi
Course Objectives ................................................................................................ vi
Classroom Checklist............................................................................................ vii
Section 1: Combined Cycle Process ........................................................................1
Section 2: HRSG Fundamentals .............................................................................5

Water to Steam Conversion ..................................................................................5
Heat Transfer Principles......................................................................................10
Boiler Circulation .................................................................................................14

Section 3: HRSG Design and Functionality...........................................................18
HRSG Project Summary .....................................................................................18
Section 4: Components and Description ...............................................................22
Low Pressure System .........................................................................................22
Intermediate Pressure System ............................................................................25

High Pressure System.........................................................................................27
Reheater .............................................................................................................30
Auxiliary Valves...................................................................................................30
Gas Side Flow Path and Components.................................................................30
Safety Valves ......................................................................................................31

Selective Catalytic Reduction System .................................................................32
Drum Level Control .............................................................................................34
Section 5: Operating Procedures and Guidelines .................................................40

Pre-operation ......................................................................................................40
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Initial Filling .........................................................................................................41
Cold Start-Up ......................................................................................................42

Warm/Hot Start Up ..............................................................................................47
Shutdown to Drain...............................................................................................49
Shutdown to Warm/Hot Layup.............................................................................49
Emergency Procedures.......................................................................................52
HRSG Troubleshooting Chart..............................................................................55

Section 6: Inspection and Preventative Maintenance............................................58
HRSG Inspection Recommendations ..................................................................63
Appendix A: Worksheets.......................................................................................68
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TABLE OF FIGURES
Figure 1: Simple Combustion Turbine Cycle ...........................................................2
Figure 2: Combined Cycle Power Plant ...................................................................3
Figure 3: Combined Cycle Efficiency .......................................................................4
Figure 4: Combined Cycle Plant .............................................................................5

Figure 5: Latent Heat of Fusion................................................................................6
Figure 6: Latent Heat of Vaporization/Condensation................................................7
Figure 7: Sensible and Latent Heat..........................................................................7

Figure 8: Pressure/Temperature Relationship..........................................................9
Figure 9: Heat Transfer Loss ................................................................................12
Figure 10: Typical Temperature Profile Across Tube Wall .....................................13

Figure 11: . Temperature Profile Across Tube Wall with Internal Deposit..............13
Figure 12: Temperature Profile Across Tube Wall with External Deposit ...............13
Figure 13: Temperature Limitations for Typical Tube Materials..............................14

Figure 14: Natural (Thermal) Circulation ...............................................................14
Figure 15: Circulation Schematic for Natural (Thermal) Circulation........................15
Figure 16: Density of Water to Steam vs. Pressure................................................16

Figure 17: Typical Static Head in a Boiler - Constant Circulation Ratio of 4.0 ........16
Figure 18: HRSG Schematic.................................................................................20

Figure 19: Temperature Profile .............................................................................21
Figure 20: Three Element Drum Level Control......................................................35
Figure 21: HRSG Design Sample .........................................................................39
Figure 22: Inlet Duct Casing/Liner Assembly ........................................................59

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Figure 23: Serrated Finned Tubes ........................................................................60
Figure 24: Vibration Fatigue Appearance..............................................................60

Figure 25: Maintenance Damage Appearance......................................................61
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Preface
This introductory course covers Heat Recovery Steam Generator design and
functionality. Component description and process diagrams are coupled with
learning activities to provide the student with basic knowledge of Heat Recovery
Steam Generator equipment and operation.
Course
Objectives
Course Objectives:
Upon successful completion of this course, the student will be able to:
1. Draw a simple process diagram of a combined cycle unit and describe the
power plant’s basic features. Describe the purpose and function of the
HRSG Unit as it relates to the combined cycle process.
2. Describe how water is converted to steam, sharing fundamental principles
including: steam characteristics, principles of heat transfer, main factors
effecting heat transfer, and boiler circulation.
3. Given a model unit, identify the major components of an ALSTOM Power
horizontal, top supported HRSG unit. Discuss design and functionality of
each component including: low pressure system, intermediate pressure
system, high pressure system, reheater, extractions, auxiliary valves, gas
side flow path, safety valves, SCR System, drum level instruments and
control.
4. Given a feedwater and chemical treatment process flow diagram, discuss
the typical indicators and main control points used by operators.
5. Explain the critical operating parameters of the unit and discuss basic
troubleshooting.
6. Describe start-up, operation and shutdown activities, identifying the
equipment that is controlled and manipulated by the operators. Discuss
emergency trip conditions and response.
7. Identify areas to inspect and possible inspection findings.
8. Describe personal safety procedures that are required when at a customer
site.
9. Describe material requirements and constraints including jurisdiction
definitions and minimum code requirements.
10. List manufacturing, transportation and erection constraints.
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Classroom Checklist
1. Draw a simple line diagram of a Combined Cycle Power Plant.

2. Mark up an HRSG general arrangement drawing, labeling major
components.
3. Describe component features found on the given Unit Material Diagram.
4. Draw a simple line diagram of an HRSG Unit.
5. During a field walkdown, identify major components.
6. Follow safety procedures while in the field.
7. Complete an equipment and valve list, explaining operator actions for start-
up, shutdown and operation.
8. Mark-up a feedwater chemical treatment flow diagram, labeling equipment
and control points.
9. Match applicable constraints for a given material list.
10. Match applicable constraints for a given manufacturing, transportation and
erection list.
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Section 1: Combined Cycle Process
Electricity is produced using a variety of energy sources: Fossil Power, Nuclear

Power, Hydraulic Power and Wind Power. Fossil Power includes traditional
fossil-fueled boiler/steam-turbine as well as combustion turbine and combined
cycle units. All of these power sources are used to drive an electrical
generator.
The process of making electricity is a series of energy conversions. A typical

fossil or combustion turbine process includes three major steps:
§ Heat or chemical energy converted to thermal energy

§ Thermal energy to mechanical energy
§ Mechanical energy converted to electricity
In a combustion turbine power plant (simple cycle):
1. Air enters the combustion turbine compressor section where the

pressure is raised.
2. The compressed air enters the combustion chamber where fuel (heat
energy) is added. The combustion process converts the heat energy
into thermal energy, in the form of hot combustion gas.
3. The hot combustion gas is forced across a series of turbine movable-
blades, which turns the turbine rotor. Thermal energy is converted to
mechanical energy at this point.
4. The generator, coupled to the same rotor, turns and generates
electricity.
A simple combustion turbine cycle is shown in figure 1.
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Figure 1: Simple Combustion Turbine Cycle
This process of energy conversions produces electricity and waste heat. As

with any chemical reaction, not all the energy is converted to useful work. Each
step produces a quantity of work and a quantity of waste heat. The challenge is
to minimize or use this waste heat to do useful work.
A combined cycle power plant will use the waste heat to produce additional
thermal energy. The waste heat flows through a steam generator, commonly
called an HRSG, Heat Recovery Steam Generator.
1. The exhaust gas from the combustion turbine flows into a duct and across a
series of steam generator tubes that make up the HRSG Unit.
2. Heat energy in the exhaust gas is converted to thermal energy when the
water in the HRSG Unit generates steam.
3. The water in the HRSG tubes is converted to steam that will flow to a steam
turbine that drives another generator (or provides more mechanical work on
the same rotor of the combustion turbine generator).

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Figure 2: Combined Cycle Power Plant
The Steam Turbine Generator (STG) converts a portion of the thermal energy
into electricity and the large volume of low pressure steam that is left over, is
collected in the condenser. The condenser is the most sensible method to
collect the steam, which still has value to the process. The steam is condensed
to water, which can be pumped back to the HRSG Unit. This water is warmer
and doesn’t require chemical treatment as compared to make-up water. The
condenser is the largest heat loss in the process, but necessary, since the large
volume of steam typically has no useful value to the process, as is.

HRSG
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The simple combustion turbine power plant (30 – 35 % efficiency) improves to a

combined cycle power plant with an efficiency of 50 % or better. Much of the
remaining waste heat is a necessary part of the equipment design.
Figure 3: Combined Cycle Efficiency

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Section 2: HRSG Fundamentals
The HRSG unit is a unique type of boiler, but follows many basic boiler
principles. The function of a boiler is to produce a specific amount of steam at
a constant pressure and temperature from a specific amount of feedwater.
Figure 4: Combined Cycle Plant
Water to Steam
Conversion
Water can transition from its liquid state to a solid (ice) or gas (vapor). Steam
generation is only concerned with the liquid and vapor forms. Steam results
from adding sufficient heat to water, causing it to vaporize or turn into a gas
vapor. This occurs in two steps:
§ The addition of heat sufficient enough to raise the temperature of

water to the boiling temperature.
§ A continuing addition of heat to change the physical state of water
from a liquid to a gas (steam).
To quantify the amount of heat needed a measurement system has been

defined. The following terms will be used to discuss the process of converting
water to steam.
Thermal capacity (specific heat) is the quantity of heat required to produce a

unit change in temperature. Water has a high thermal capacity. This means
that a great amount of heat is required to cause a temperature change in water.
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Another characteristic of water is that it cools slowly in the process of giving up

absorbed heat.
Specific heat is the term used in power generation for thermal capacity.
Specific heat is the amount of heat in British thermal units, Btu, required to raise
the temperature of one pound of water one degree Fahrenheit (°F). It takes
»one Btu to raise the temperature of one pound of water one degree F. Other
substances may require either more or less heat to raise one pound by one
degree F.
Enthalpy is the measure of the total stored internal energy of a substance, such
as water or steam. Steam Table is a useful chart that lists the enthalpy in Btu/lb
of saturated liquid (hf), along with saturated and superheated steam at various
pressures and temperatures. The term Btu/lb represents the amount of heat
transferred to the water/steam from the combustion gases (heat energy).
Enthalpy changes are a function of temperature and pressure. The steam

tables show the trends in Btu when going from a low pressure to a high steam
pressure.
Steam Generation Process
Latent Heat of Fusion

Latent heat of fusion is defined as the amount of heat required to melt one
pound of ice at 32°F to one pound of water at 32°F. This latent heat or "hidden
heat" produces a change in state of the water instead of a change in
temperature. 144 Btu are needed to convert one pound of ice into one pound
of water at 32°F and 14.7 psig or 29.92 Hg, the normal atmospheric pressure or
absolute pressure. This process is depicted in Figure 5.
Figure 5: Latent Heat of Fusion
Latent Heat of Vaporization

Latent heat of vaporization is defined as the amount of heat required to change
one pound of liquid water to one pound of steam (vapor). When additional heat
is added to water at its boiling point, the temperature of the water remains
constant, but the physical state is changed. One pound of water at 212° F,
which is the boiling point of water at 14.7 psig, requires 970 Btu to change into
one pound of steam at 212°F. This process is depicted in Figure 6.

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Figure 6: Latent Heat of Vaporization/Condensation
Latent Heat of Condensation

Latent heat of condensation, also shown in Figure 6, refers to the condition
where a pound of steam at 212°F is cooled (heat is removed) to form a pound
of liquid water at 212°F. The energy lost in going from a pound of steam to
water is 970 Btu/lb.
Sensible Heat
When the flow of heat is not reflected in a temperature change (latent heat), it is
absorbed in the fluid or substance and increases the kinetic energy of the
molecules of the substance. This is called sensible heat. Water at 32°F will
absorb 180 Btu of sensible heat per pound when raising the water temperature
to 212°F. See Figure 7.
Figure 7: Sensible and Latent Heat

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Heat Flow
Heat is the flow of thermal energy. When heat is added or removed,
temperature differentials are formed so that thermal energy can flow from one
substance or area to another. Sensible heat and latent heat are merely two
effects produced by heat, not different kinds of heat.
When the flow of heat is not reflected in a temperature change (latent heat), it is
absorbed in the fluid or substance and increases the kinetic energy of the
molecules of the substance.
Knowledge Check
Applying these fundamentals to the HRSG, heat energy must be added to raise
the temperature of water to the boiling point and then continue to add heat
energy to convert all the water to steam.
Remember, the thermal energy will be used to drive a turbine. The amount of
work the turbine can do, is dependant on the amount of thermal energy
available. Therefore, if more heat energy is added, to raise the temperature of
the steam, more thermal energy will be produced.
Steam Characteristics
A steam turbine is an expensive piece of equipment. The steam quality that it
demands to produce work is a critical parameter of the HRSG.
What is steam?
Steam is an invisible gas generated by adding heat energy to water in a boiler.

Enough energy must be added to raise the temperature of the water to the
boiling point. Then additional energy, without any further increase in
temperature, changes the water to steam.
The heat energy is not lost but stored in the steam ready to be released to heat
air, cook beer, press pants or generate electricity.
Steam is a very efficient and easily controlled heat transfer medium. It is most
often used for transporting energy from a central location (the boiler) to any
number of locations in the plant where it is used to do work.
Quality of Steam
The proportion, by weight, of "dry" vapor in a steam and water mixture is termed
the quality of steam. Steam quality is expressed in percentages. If a quantity
of steam contains 90% steam and 10% water vapor, the mixture has a quality
of 90%.
Saturated Steam
Saturated steam is steam soaked with all the heat it can hold at the boiling
temperature of water.
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Dry saturated steam vapor essentially contains very little moisture (dependent
upon its quality), and is at saturated temperature for the given pressure. Its
total heat content, or enthalpy, is equal to the heat of the liquid plus the heat of
vaporization.
Pressure and Temperature Relationship
When water is heated to the boiling point in a closed vessel, the vapor released
causes the pressure to increase in the vessel. With the increase in pressure,
the boiling temperature of the water also increases.
The temperature at which water boils at a given pressure is termed the

saturation temperature. For each saturation temperature, there is a
corresponding pressure called the saturation pressure. Figure 8 depicts the
relationship between saturation temperature and saturation pressure.
Figure 8: Pressure/Temperature Relationship
Superheated Steam
Steam heated above its corresponding saturation temperature at a particular
pressure is called superheated steam. Superheated steam contains no
moisture, and will not condense until its temperature has been lowered to that
of saturated steam at the same pressure.
Degree of superheat refers to the temperature difference in degrees Fahrenheit

between the steam at the superheater outlet, and its corresponding saturation
temperature (steam drum outlet) at a given pressure.

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For example, consider a superheater outlet steam pressure of approximately

72.5 psi and a superheater outlet steam temperature of approximately 572°F.
The corresponding saturation temperature at that pressure is approximately
318oF. Therefore, the degree of superheat is 572°F minus 318°F, equaling
254°F.
Note: It must also be recognized that there is a loss in steam pressure between
the drum steam pressure and the superheater outlet steam pressure.
Knowledge Check
To convert a pound of liquid water to steam takes more than six times the
amount of heat that it requires to bring that same pound of water from freezing
temperature to boiling. That is a lot of heat energy!
This is the key that makes steam so attractive. Because the reverse holds true
also. When the phase change goes the other way...that is, when the steam
condenses into liquid, it gives off just as much heat as was put into to the liquid
water to cause it to change to steam in the first place.
Since so much energy is absorbed during the transition from liquid to vapor, the
steam can be transported via a pipe, and then condensed where the heat is
needed. When the steam condenses, the "heat of condensation" is released.
The net effect, especially if the lines transporting the steam are well insulated,
is practically the same as if the heat source itself were located at the end of the
pipeline, where the steam condenses and gives off it’s tremendous heat
content.
Superheated steam has three advantages over steam that is not superheated:
§ It increases the efficiency of the turbine.

§ It prevents damage to turbine blades from condensation.
§ It is able to travel through long pipelines with little or no condensing.
Heat Transfer
Principles
The process of transferring thermal energy can only occur if it originates from
an area or material of one temperature to an area or material of a lower
temperature. Heat transfer is vital to the operation of the power plant cycle and
occurs in many locations throughout the plant.
Heat Transfer Modes
Conduction
When heat passes through a solid object, quickly moving molecules in the hot
portion collide with and give up some energy to slower molecules in the cooler
portion. This type of heat transfer is called conduction.

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Radiation
Heat transfer occurs via radiation when electromagnetic waves from a heat
producing source strike a surface, and give up energy to the molecules in that
surface. Burning fuels give off radiant energy.
Convection
When a heated fluid or vapor moves to a cooler region by circulation resulting
from density differences between the hot and cold areas within the fluid or
vapor, this is called convection.
Main Factors Affecting Heat Transfer
Differential Temperature (DT)

The temperature difference between a high temperature source and a low
temperature source is called differential temperature (DT). A higher DT will
result in a greater amount of heat transfer.
Thermal Conductivity
Thermal conductivity is an indication of how well a material absorbs and
transfers heat. A higher value of thermal conductivity means a material is
capable of transmitting heat at a faster rate than a material with a low thermal
conductivity.
Surface Area
Surface area is the area of a low temperature source that is placed in contact
with a source of higher temperature. A larger exposed area will result in a
higher heat Transfer Coefficient.
The heat transfer coefficient is a constant factor, which mainly depends on the
physical properties of the heat transferring mediums such as gases, solids and
metal tubes, and the gas velocity in the boiler. Materials are selected and
arranged in the boiler according to their various heat transfer properties.
Pinch Point
The difference between the gas temperature leaving an evaporating section
and the temperature at which boiling is occurring (saturated water temperature)
is called a pinch point. The pinch point strongly influences the amount of heat
transfer surface in the evaporating section. Current HRSG designs use pinch
points in the 15° to 25°F range.
Approach Temperature
The approach temperature is the difference between the saturated-water
temperature in an evaporating section and the incoming feedwater temperature.
The approach temperature influences the amount of surface required for an
economizer section, with exponentially increasing amounts required for very
low approach temperatures. Current HRSG economizers have approach
temperatures in the 15° to 25°F range. Many other operating conditions can
occur at off-design points, including start-up. Some conditions will result in
steaming at the exit of the economizer, such that it acts as an evaporative
surface.

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Materials
Metals have good thermal conductivity. The number and arrangement of the
tube assemblies placed in a boiler are selected to provide the proper tube
surface area which is expressed to the hot solids/gases so that the correct
amount of heat is transferred to the water/steam to obtain design steam
pressure and temperatures with design combustion temperatures.
Fiberglass, silica block, and certain refractory compounds are used where heat
transfer is not desired. These materials, called insulators, have low thermal
conductivity and help to reduce heat transfer.
Improper insulation in the form of ash and/or dust and internal tube deposits
can be very detrimental to boiler heat transfer, as indicated in Figures 9 - 12.
Deposits on the external surfaces of boiler tubes have lower thermal
conductivity than the tube metal. A higher differential temperature is required to
pass the proper amount of heat through the deposits to the water/steam inside
the tubes.
The reduction in heat flow from the tube to the boiler water/steam increases the
average tube metal temperature, which can lead to tube failures from
overheating. Temperature limitations for typical tube materials are shown on
Figure 13.
Figure 9: Heat Transfer Loss

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Figure 10: Typical Temperature Profile Across Tube Wall
Figure 11: . Temperature Profile Across Tube Wall with Internal Deposit
Figure 12: Temperature Profile Across Tube Wall with External Deposit

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Figure 13: Temperature Limitations for Typical Tube Materials
Boiler Circulation
Boiler circulation is defined as the movement of water, a mixture of steam and

water, or steam through boiler tube circuits. There are two types of circulation:
§ Natural or "thermal" circulation

§ Forced or "controlled" circulation
Natural Circulation
In natural circulation boilers, circulation is accomplished without the use of a
circulating pump.
The density difference between steam and water (thermal head) is the driving
force in a natural circulation boiler (Figure 14).
Figure 14: Natural (Thermal) Circulation

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Cold side: The density of saturated water in the downtakes (also called
downcomers) will range between 60 lb/ft3 and 30 lb/ft3, depending on the
corresponding pressure and temperature in the boiler steam drum.
Hot side: The steam/water mixture density in the waterwalls will be

approximately 25 lb/ft3. Variations in boiler pressure have a lesser effect on the
mixture density.
Figure 15: Circulation Schematic for Natural (Thermal) Circulation
As boiler pressure increases, the difference between the densities of water and
steam, which is the motive force for natural circulation boilers, becomes smaller
(Figure 15).
Thermal head differential is the resulting differential ranges between

approximately 25 psi and 10 psi, with the greater differential being possible in
lower pressure boilers (Figures 16 and 17).

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Figure 16: Density of Water to Steam vs. Pressure
In addition to the fact that there is less motive force in a higher-pressure boiler,
there are also other factors in a natural circulation boiler, which oppose
circulation. These are:
§ Friction between water and tube metal

§ Friction between water and scale deposits in tubes
§ Friction in tube bends
§ Friction in lower drum and headers
§ Friction around upper drum internals
§ Friction in the steam and water separating equipment
Figure 17: Typical Static Head in a Boiler - Constant Circulation Ratio of 4.0

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Tube Flow
If there is not enough cooling flow through a tube, the metal will overheat and
burst. By looking at the basic equation for flow, we can see two things that
most affect flow.
Q = A x V, where Q is flow, A is area (cross-sectional), and V is velocity
Natural circulation boilers must have large diameter tubes, to reduce the
resistances to flow and maintain adequate circulation and tube cooling.
The velocity relates to the force, and the force is dependent on the density
differential (thermal head) and the total height of the boiler circuit. At higher
pressures, flow velocities are insufficient for adequate cooling in a natural
circulation boiler.
Forced Circulation Principle
Circulation through the boiler is provided by an external mechanical force such
as a circulating pump located in the downcomer circuit from the steam drum.
Circulating pumps provide additional head to supplement the existing thermal
head. This ensures adequate cooling or circulation throughout the boiler at all
times. Boilers of this type are designed to operate at higher pressures than
natural circulation boilers.
Circulation Ratio
Circulation ratio is defined as the weight of water entering the downcomer,
divided by the weight of steam in the water/steam mixture leaving the water wall
tube circuits.
Because circulation is dependent on the thermal head, which is dependent on

boiler pressure, the flow of water into the downcomer increases as load
decreases. At low loads of 50% of Maximum Continuous Rating (MCR) or less,
the circulation ratio will be much higher since there is less steam being
generated.
Natural Circulation boilers are generally designed for a circulation ratio of "5”
equaling a circulation ratio of 5 to 1. For example, for every 25-lb. of water
entering the downcomer, there could be as much as 5 lb of steam leaving.

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Section 3: HRSG Design and Functionality
A Heat Recovery Steam Generator (HRSG) is used to recover heat that

otherwise would be lost in the exhaust from a gas turbine. This heat is then
used to generate steam that will drive a steam turbine or be used in a process.
The addition of an HRSG and a steam turbine boosts total output of electricity
by 30 percent or more over the traditional gas turbine operating in a single cycle
mode. Efficiency increases with the increased output.
HRSG Project
Summary
One standard configuration and an effective learning example, is the gas

turbine, combined with a triple-pressure HRSG with reheat and a steam turbine.
Many of the descriptions in this manual refer to the triple-pressure HRSG Unit.
The HRSG utilizes the hot exhaust gases from the gas turbine to generate
steam in three cycles; high pressure, intermediate, and low pressure. Steam
produced is directed to the steam turbine. The HRSG is also equipped with a
reheater section to reheat the high-pressure turbine exhaust steam before it
passes to the intermediate pressure turbine section.
The Predicted Performance Summary on the next page provides typical

operating conditions for a triple-pressure HRSG.
Schematic Overview
Figure 18 provides an overview of the fluid flow paths of a typical triple-pressure
HRSG Unit. Rather than simply being a radiator, the integration of this
complex heat transfer system results in one of the most cost effective and
efficient electric power production units in the world.
HRSG Temperature Profiles

The HRSG Unit is designed to maximize heat transfer. The designers have
sequenced the components relative to the drop in gas temperatures from
HRSG inlet to outlet. Future losses in performance can best be identified and
remedied when analyzing the changes in the temperature profiles.
Commissioning identifies the expected temperatures for varying load situations.
Figure 19 shows a sample of expected temperatures for full-load, steady state
operation.

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Case Number/Performance Mode 2/Design 1/Off-design 3/Off-design

Ambient Temperature deg F 45 86 0
Gas Turbine Fuel Natural Gas Natural Gas Natural Gas
O2 12.48 12.17 12.65
Exhaust Gas N2 74.59 72.88 75.09
Constituents CO2 3.93 3.85 3.91
% by Volume H2O 8.11 10.24 7.45
Ar 0.89 0.87 0.90
Turbine Exhaust Flow lb/hr 3,634,000 3,321,000 3,883,000
Turbine Exhaust Temp deg F 1,109 1,143 1,070
Casing Heat Loss kW 1,302 1,254 1,324
HP Steam Flow (1) lb/hr 408,115 * 398,924 405,660
HP Steam Temperature (+/- 10°F) deg F 1,054 * 1,054 1,022
HP Steam Pressure at NRV outlet psia 1,887 1,866 1,873
HP Cascading Blowdown Flow lb/hr 4,110 3,830 4,090
HP Pinch Point deg F 16 15 17
HP Approach Temp deg F 12 12 9
HP Desuperheater Spray lb/hr 1,560 19,366 579
HP Feedwater Flow lb/hr 412,225 402,754 409,750
HP Feedwater Temp deg F 308 305 312
RH Steam Flow lb/hr 480,440 465,223 489,818
RH Steam Temperature deg F 1,030 1,039 998
RH Steam Pressure at HRSG Outlet psia 357 351 349
RH Desuperheater Spray lb/hr 0 1,505 0
Cold RH Steam Flow lb/hr 394,640 385,725 392,288
Cold RH Steam Temperature deg F 643 637 617
IP Steam Flow (1) lb/hr 85,800 * 77,990 97,530
IP Steam Temperature (+/-10°F) deg F 579 * 578 577
IP Steam Pressure at NRV outlet psia 383 377 375
IP Continuous Blowdown Flow lb/hr 865 790 985
IP Pinch Point deg F 20 18 22
IP Approach Temp deg F 6 6 5
IP Water Flow to Fuel Preheater lb/hr 39,850 38,750 38,750
IP Water Temperature to Fuel Preheater deg F 437 435 436
IP Feedwater Flow lb/hr 126,515 117,530 137,265
IP Feedwater Temp deg F 307 304 311
LP Steam Flow (1) lb/hr 58,420 * 54,655 62,117
LP Steam Temperature (+/- 10°F) deg F 491 * 489 495
LP Steam Pressure at NRV outlet psia 65.7 63.7 70.0
LP Pinch Point deg F 11 10 12
LP Approach Temp deg F 16 15 17
LP Drum Operating Pressure psia 73 69.5 77.7
FW Preheater Outlet Water Temperature deg F 293 293 298
FW Preheater Inlet Water Temperature deg F 135 135 130
FW Preheater Recirculation Flow lb/hr 173,000 135,000 206,000
FW Preheater Supply Water Temperature deg F 89 98 73
Feedwater Flow to LP drum lb/hr 597,160 576,444 609,132
Gas Temp Leaving HRSG deg F 187 184 186
Static Gas Side Pressure Loss (2) in WG 15.00* 12.6 17.0
Inside Fouling Factor hr-ft²-°F/Btu 0.0001 0.0001 0.0001
Outside Fouling Factor hr-ft²-°F/Btu 0.0010 0.0010 0.0010
1) Steam production rates based on specified feedwater inlet temperature.

2) Static gas side pressure loss from HRSG ductwork inlet to stack outlet including SCR, stack silencer and stack damper.
3) CRH flow=HP flow*0.967
Stack height: 155ft. Site Elevation: 62 ft.
(*) These points are guaranteed, other are predicted.

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Figure 18: HRSG Schematic

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Figure 19: Temperature Profile

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Section 4: Components and Description
This section will use the standard configuration of a triple-pressure heat

recovery steam generator (HRSG) for all component descriptions. The triple-
pressure HRSG unit consists of three boiler systems operating at different
pressure levels, and a reheater. The vertically hung heat-transfer tube bundles
are arranged in the duct space with exhaust gas flowing horizontally. The outlet
duct of the Gas Turbine Unit is connected to the inlet duct of the HRSG. The
layout and design pressures allow for natural circulation of water and steam.
Low Pressure
System
The LP System is designed to produce low-pressure steam for use in plant

processes or the low-pressure steam turbine. The LP System is physically
located in the backend of the HRSG, closest to the stack. The steam is
typically superheat with a pressure of 75 psia.
The LP System includes: economizer (FW Preheater), steam drum, evaporator,

superheater and associated valves and pumps. Condensate is the water
source to the LP System.
Condensate
The water supply to the HRSG System is condensate from the steam turbine
generator process. The Steam Turbine Generator converts the thermal energy
of steam by expanding and forcing it across several stages of rotating blades.
The large volume of low pressure exhaust steam from the last blade stage has
thermal energy value, but there is no reasonable mechanism to transport or
force this low pressure steam back into the LP Steam Drum. Therefore, the
exhaust steam dumps into a condenser. The steam is condensed, giving up
some of it’s thermal energy value (designed loss) so that the condensate can
be pumped back into the LP System as boiler feedwater. The condensate is a
clean source of water that is also warmer than make-up water.
LP Economizer (Feedwater Preheater)

The condensate is pumped to the LP economizer which is a shell and tube type
heat exchanger. The economizer is arranged in bundles, each bundle having
an inlet manifold, tube bank and outlet manifold. The condensate flows to the
inlet manifold, through the tubes and to the outlet manifold.
A typical economizer arrangement both parallel and series design. Parallel

meaning that some of the water flows through each tube or bundle. Series
meaning all the water flows through each tube or bundle. The economizer
arrangement in figure 9 has two parallel flows and each flowpath passes
through four bundles arranged in series. Feedwater flows from the economizer
outlet to the LP steam drum.

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The condensate that enters the LP economizer is now called feedwater. The
feedwater flows counter-current to the heat source, hot combustion gas. The
cooler feedwater enters the first series of tube bundles located in the last gas
pass, closest to the stack. The feedwater temperature is increased by
convection heat transfer from the hot combustion gas passing over the tubes.
The economizer is designed to raise the temperature of the feedwater close to

the LP steam drum saturation temperature. Feedwater temperature increases
to 290 degrees entering the LP steam drum and the combustion gas
temperature to the stack is approximately 200 degrees.
Temperature control is critical to HRSG operation and component life. A

temperature control loop has been designed to manage the economizer
temperature during low flow and start-up conditions. During start-up and low
flow conditions, colder make-up water is since condensate is not available.
§ Low temperatures in the economizer will also cause condensation

on the gas side, allowing moisture to form on the tubes and risk
corrosion of the metal.
The temperature control loop includes an economizer recirculation pump, flow

control valve and a single element temperature sensor(probe). The economizer
recirculation pump takes suction from the economizer outlet manifold and
pumps feedwater in two paths: to the LP Steam drum and the recirculation line.
The recirculation line flow control valve receives a signal from the temperature
element on the economizer inlet manifold. If the temperature is below the
desired setpoint, the control valve will open and recirculate some of the
feedwater back to the economizer inlet manifold.
Component Equipment List

LP Economizer Supply Flow Measuring Orifice
Flow Control Valve
Check Valve and Stop valve
Economizer Bundles Vent Valves
Drain Valves
LP Steam Drum – Water Side

Feedwater enters the LP Steam Drum and is distributed along the entire length
of the drum by the feedwater distribution header. Nozzles in the distribution
header direct the feedwater in the downward direction in order to minimize
turbulence and aid in circulation. The feedwater mixes with the water in the
drum and is directed to the LP downcomers. The mixed water is now termed
boiler water.
A chemical feed line, installed in the drum, injects chemicals to maintain boiler
water chemistry.

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Downcomers
The LP downcomers originate at the LP steam drum and terminate at the
evaporator inlet manifold. These tubes (3) are designed to provide natural
circulation of the boiler water to the lower evaporator inlet manifold.
LP Evaporator
The evaporator (LPEVAP) is arranged with all circuits originating at the LP
evaporator inlet manifolds. The vertically arranged evaporator circuits are
placed in the hot gas pass. The water temperature is at boiling point, therefore,
convection heat transfer generates steam. The steam-water mixture flows
upward to the evaporator outlet manifolds. The steam-water mixture then
passes from the LP evaporator to the LP steam drum through riser tubes.

LP Evaporator Inlet Drain Valves (double)
Intermittent Blowoff Valves
Steam Sparging Line
LP Steam Drum - Steam Side

The steam-water mixture flows from the evaporator riser tubes into the steam
drum. The steam is directed toward two rows of separators. Steam-water
separation is performed in three stages:
§ Steam-water enters the bottom of the separators and is forced

upward through the primary separators. Centrifugal force separates
the steam from the water. The water is thrown against the sides of
the separator and drains back into the drum.
§ Next, the steam must go through a tortuous path between tightly
spaced corrugated metal plates (secondary separators) above the
separators. The velocity in this stage is low and additional water
drops out.
§ Lastly, the steam takes a twisting path through the corrugated plate
dryers where water droplets are forced out. Any water removed at
this stage is collected and returned to the steam drum through a
drainpipe.
Steam exits the top of the LP steam drum dryer through steam outlets and is
directed to the LP Superheater Section of the HRSG.

LP Drum Safety Valves (2)
Drum Vent (double)
Pressure Transmitter and Gauge
Level Gauge and Level
Transmitters (3)

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LP Superheater Section
The saturated steam leaves the LP steam drum outlet header and enters the
superheater (LPSH) through the superheater inlet manifold and then on to the
superheater circuits. The steam temperature is increased, drying any moisture
in the steam and boosting the steam’s thermal energy. From the superheater
outlet manifold, the steam is directed to the LP steam line.
The superheater is physically located ahead of the IP evaporator section, in a

hotter gas pass. The steam temperature is raised from 300 degrees saturation
temperature to 490 degree superheat temperature.

LP Superheater Safety Valve (1)
Drain Valves
Non-Return Valve
Motor Stop valve
Pressure and Flow Instrumentation
Temperature Instrumentation
Intermediate
Pressure System
The IP System is designed to produce intermediate-pressure steam for use in

the IP steam turbine stages. The IP System is physically located ahead of the
LP system in a hotter gas pass. The steam is superheated with a pressure of
380 psia and temperature of 580 degrees.
Th LP System consists of: economizer, steam drum, evaporator, superheater

and associated valves. Condensate is the water source for the IP System.
IP Economizer
Condensate is supplied from the IP feedwater inlet line and flows through a two
pass economizer. Depending on the condensate pump design, the process
mi8ght include an IP feedwater pump. Water enters IP economizer 2-inlet
manifold and flows through the tube bundle. From the economizer 2-outlet
manifold the feedwater is directed to the IP economizer 1-inlet manifold and
exits at the economizer outlet manifold. The warmed IP feedwater then enters
the IP steam drum.
Refer to Figure 18 for location of the economizer bundles. The bundles are
strategically placed to meet the heat transfer design. The feedwater
temperature exits the economizer at 307 degrees, which is close to saturation
temperature in the IP steam drum.

IP Economizer Inlet Control Valve with bypass
Check Valve
Motor Stop valve
Drain Valves
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IP Steam Drum – Water Side

In the steam drum the incoming feedwater is distributed along the entire length
headers direct the incoming feedwater in the downward direction in order to
minimize turbulence and aid in circulation. The feedwater mixes with the water
in the drum and is directed to the three IP downcomers. The water is now
termed boiler water.
A chemical feed line, installed in the drum, allows for injection of chemicals
used to maintain boiler water chemistry.
Downcomers
The IP downcomers originate at the IP steam drum and terminate at the
evaporator inlet manifold, directing the boiler water to the evaporator. These
tubes (3) are designed to provide natural circulation of the boiler water to the
lower evaporator header.
IP Evaporator
The evaporator is arranged with all circuits originating at the IP evaporator inlet
manifold. The vertically arranged evaporator circuit includes several bundles of
tubes. Again, the water temperature is at boiling point, therefore, convection
heat transfer generates steam. The steam-water mixture flows upward to the
evaporator outlet manifolds. The steam-water mixture then passes from the IP
evaporator to the IP steam drum through riser tubes.

IP Evaporator Inlet Drain Valves (double)
Automatic Blowdown Valves
Steam Sparging Line
IP Steam Drum – Steam Side

Saturated steam/water mixture from the evaporator enters the drum and is
directed to the two rows of separators. Steam-water separation is performed in
three stages:
§ Upon reaching the bottom of the separators, the mixture is forced

upward through the primary separators, separating water from
steam by centrifugal force. Water thrown against the sides of the
separator drains back into the drum.
§ Next the steam must go through a tortuous path between tightly
spaced corrugated metal plates (secondary separators) above the
separators. The velocity in this stage is low and the additional water
drops out.
§ Lastly, the steam must take a twisting path through the corrugated
plate dryers where the last water droplets are forced out. Any water
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removed at this stage is collected and returned to the drum reservoir
through a drainpipe.
Steam leaves the drum 99.9% pure and exits through three saturated steam
outlets located on the top of the drum. Steam leaving the IP drum passes
through the IP superheater.

IP Drum Safety Valves (2)
Drum Vent (double)
Level Gauge and Level Transmitters (3)
Continuous Blowdown
Cascading Blowdown from HP Drum
IP Superheater
Steam enters the superheater (IPSH) through the superheater inlet manifold
and then on to the superheater circuits. From the superheater outlet manifold,
the steam is directed to the cold reheat steam line. This steam will mix with the
steam leaving the HP turbine exhaust and flow to the Reheat Section of the
HRSG.
The IP superheater steam temperature is designed to match the cold reheat

temperature and pressure, 580 degrees and 380 psia. Refer to Figure 18 for
location of the IP superheater bundles.

IP Superheater Safety Valve (1)
Non-Return Valve
Drain Valves
Motor Stop valve
Pressure and Flow Transmitters
High Pressure
System
The HP System is designed to produce high-pressure steam for use in the HP

steam turbine stages. The HP System has components spaced all through the
HRSG unit, depending on the heat transfer needs of each component. The
steam is typically superheated with a pressure of 1880 psia and temperature of
1,050 degrees.
Th HP System consists of an economizer, a steam drum, an evaporator,

superheater, desuperheater and associated valves. Condensate is the water
source to the HP System.

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HP Economizer
The condensate is first pumped to the high-pressure feedwater pumps and then
to the economizer. Feedwater enters economizer 4-inlet manifold passes
through vertical tube bundles to the outlet manifold. The flow is directed from
economizer 4 to economizer 3, 2, and 1, and finally to the HP steam drum.
Refer to Figure 18 for location of the economizer bundles. The bundles are
strategically placed to meet the heat transfer design. The feedwater
temperature exits the economizer at 310 degrees, which is close to saturation
temperature in the HP steam drum.

HP Economizer Inlet Control Valve with bypass
Check Valve
Motor Stop valve
Drain Valves
HP Steam Drum – Water Side

In the steam drum the incoming feedwater is distributed along the entire length
headers direct the incoming feedwater in the downward direction in order to
minimize turbulence and aid in circulation. The feedwater mixes with the water
in the drum and is directed to the three HP downcomers. The water is now
termed boiler water.
A chemical feed line, installed in the drum, allows for injection of chemicals
used to maintain boiler water chemistry.
Downcomers
The HP downcomers originate at the HP steam drum and terminate at the
evaporator inlet manifold, directing the boiler water to the evaporator. These
tubes (3) are designed to provide natural circulation of the boiler water to the
lower evaporator header.
HP Evaporator
The evaporator is arranged with all circuits originating at the HP evaporator inlet
manifold. The vertically arranged evaporator circuit includes several bundles of
tubes where steam is generated. The steam-water mixture then passes from
the HP evaporator to the HP steam drum through riser tubes.

HP Evaporator Inlet Drain Valves (double)
Automatic Blowdown Valves
Steam Sparging Line

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HP Steam Drum – Steam Side
Saturated steam/water mixture from the evaporator enters the drum and is
directed through separators, plates and dryers to remove the water from the
steam. The drum design is similar to the LP and IP Steam Drums.
Steam leaves the drum 99.9% pure and exits through three saturated steam
outlets located on the top of the drum. Steam leaving the HP drum passes
through the HP superheater.

HP Drum Safety Valves (2)
Drum Vent (double)
Level Gauge and Level Transmitters (3)
Continuous Blowdown
HP Superheater
Steam enters the superheater (HPSH) through the superheater inlet manifold
and then on to the superheater circuits. Steam flows through SH 3 and SH 2,
then passes through a desuperheater before entering the final pass, SH 1.
From the superheater outlet manifold, the steam is directed to the HP steam
line.
Refer to Figure 18 for location of the HP superheater bundles.

HP Superheater Safety Valve (1)
Non-Return Valve
Drain Valves
Motor Stop valve
HP Desuperheater
The desuperheater is used to control outlet steam temperatures in the HP
system. Water is sprayed into the path of the steam, reducing the steam
temperature. A desuperheater spray water control valve regulates the flow of
spray water supplied to the desuperheater.
HP steam desuperheater spray water is taken from the HP feedwater pump

discharge.

HP Desuperheater Shutoff Valves (up and downsteam)

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Drain Valves
Reheater
Cold reheat steam from the HP turbine exhaust flows into the IP steam
superheater outlet line. The steam flows through the vertically arranged reheat
circuits. All reheater circuits originate at the reheater inlet header and terminate
at the reheat outlet header. From reheater 2 the steam is routed to the RH
desuperheater for steam temperature control before entering reheater 1 for
further warming. The reheated steam is collected in the upper collection
header and routed to the IP turbine through the RH outlet header.
Steam enters the reheater at approximately 692 degrees and 397 psig. Steam
exits the reheater at approximately 1055 degrees and 397 psig.
The hot reheat desuperheater cooling water is taken from the IP feedwater
discharge line.

Reheater Safety Valve (1)
Non-Return Valve
Drain Valves
Motor Stop valve
Auxiliary Valves
Economizer sections for the Low Pressure System, The Intermediate Pressure
System, and High Pressure System are provided with Economizer Vent Valves
at the upper headers of each section. The vent valves are used to vent off air
that has become trapped in respective pressure sections while filling the HRSG
with water.
Each lower economizer header for each section is provided with a drain valve
arrangement to allow draining at shutdown. Evaporator distribution manifolds
for the LP evaporator, the IP evaporator, and HP evaporator are also equipped
with double drain valves to ensure complete draining of each evaporator
section during shutdown of the unit. One set of double valves is an intermittent
blowoff to rid the header sections of solids during operation.
Gas Side Flow Path

and Components
The HRSG can accept exhaust gas from the GT in excess of 4,000,000 lb/hr at
approximately 1132 degrees. The exhaust gas passes through the following
sections:

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§ HP Superheater 1
§ HP Reheater 1
§ HP Superheater 2
§ HP Reheater 2
§ HP Superheater 3
§ HP Evaporator
§ SCR (if applicable)
§ HP Economizer 1
§ IP Superheater
§ HP Economizer 2
§ LP Superheater
§ IP Evaporator
§ IP Economizer 1
§ HP Economizer 3
§ HP Economizer 4
§ IP Economizer 2
§ LP Evaporator
§ LP Economizer
The exhaust gas exits the HRSG at approximately 200 degrees and is
discharged to the stack.
Safety Valves
Safety valves are devices that protect the steam and water circuits of the boiler
against accidental over pressurization. They provide the final protection against
pressure part damage when other means, such as control and interlock
systems fail or cannot react fast enough.
The A.S.M.E. Boiler and Pressure Vessel Code states that safety valves are
required on every pressure vessel. The boiler code also requires that the
safety valves have a total steam relieving capacity at least equal to the rated full
load steam flow of the boiler.
Location
Fourteen spring type safety valves are typically supplied with the boiler. The
valves are listed below.
§ HP Steam Outlet
§ HP Drum 1 (2)
§ HP Drum 2
§ IP Steam Outlet

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§ IP Drum 1
§ IP Drum 2
§ LP Steam Outlet
§ LP Drum 1
§ LP Drum 2
§ RH Steam Outlet
§ RH Steam Inlet (2)
§ GTHP Econ
Pressure Settings and relieving capacities are determined by the individual

system pressures in the HRSG. Three things are considered in the
calculations: 1) the heat balances throughout the system, 2) operating and
control concepts at the plant, and 3) routing of piping and pressure losses.
The safety valve settings are designed to relieve at the drum before the
superheater.
Exhaust Piping Arrangement

The exhaust from the safety and the relief valves are not attached to the
building steel, and are free to move inside the vent pipe that vents the steam to
the atmosphere. Only the vent pipe is attached to the building steel framework.
Drains from the drip pan and exhaust vent pipe remove condensate. Vent
piping is not connected to the valve body and should discharge the steam to a
safe location.
Selective Catalytic
Reduction System
The process of Selective Catalytic Reduction (SCR) of combustion flue gases

reduces nitrogen oxides (NOx) into molecular nitrogen (N2) and water (H2O).
NOx breaks down when it reacts with a reducing agent, usually ammonia (NH3)
in the presence of a catalyst. The ammonia is mixed thoroughly with the flue
gas prior to the catalyst. The catalyst, by providing active reaction sites, allows
the reaction to occur at temperatures between 300 – 1050 degrees F. The
ammonia diffuses into the catalyst pore structure and is adsorbed onto an
active catalyst site. The NOx then reacts with the adsorbed ammonia
completing the reaction. The reaction depends primarily on available active
sites (a function of geometric surface area, pore volume, and concentration of
active catalyst component), flue gas temperature, and reagent concentration. A
well-balanced process will maintain appropriate output levels of residual NOx
and NH3.
The catalysts are extruded ceramic structures composed of inorganic oxides.

This material is titanium-tungsten based and is highly reactive to NOx. These
extruded catalysts are homogeneous, in that the entire element is composed of
a uniform distribution of catalytic material. Usually, the catalysts are assembled
into steel modules that are arranged in the SCR reactor to efficiently contact the

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flue gases during system operation. The honeycomb structure provides high
geometric surface area per unit volume.
The primary reactions describing the process are as follows:
4NO + 4NH3 + O2 ® 4N2 + 6H2O

NO + NO2 + NH3 ® 2N2 + 3H2O
6NO + 8NH3 ® 7N2 + 12H2O
The first reaction is the predominant reaction. It shows that one mole of
ammonia is consumed for each mole of NO removed. However, in an actual
system, slightly more ammonia is injected than necessary for the desired NO
removal, to account for imperfect mixing. The excess ammonia, which passes
through the catalyst bed non-reacted, is called ammonia slip.
The SCR is designed to provide an outlet NOx concentration set point while
burning natural gas.
Ammonia Supply
Commercial Grade Aqueous Ammonia (19.4% by weight ammonia) is required
in this system. The ammonia is distributed by an Ammonia Flow Control Unit
(AFCU) skid, which typically consists of the following:
§ One(1) primary blower

§ One(1) secondary blower
§ Two(2) immersion heaters
§ Instrument air line
§ Aqueous ammonia supply line
§ One(1) heater power panel
§ Two (2) vaporizer chambers
Dilution Air Supply

Two centrifugal blowers are used as the primary source of supply for the
dilution air. Each blower is designed to provide sufficient air to deliver the
ammonia in the proper concentration for the best reaction without ammonia slip.
Vaporizer
Two (2) vaporizers, typically constructed of rolled carbon steel, serve as the
housing for each heater. Each vaporizer is packed with pall rings to increase
the surface area for ammonia vaporization. As the dilution air enters the
vaporizer chamber, it is heated and used to vaporize the aqueous ammonia.
One vaporizer serves as the primary and the other as the secondary.
Electric Air Heater

An immersion heater, usually 480 volts, is contained in each vaporizer. For
high-limit protection, three type “K” thermocouples are welded to the sheath of
the heater element.
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The heater control system includes a main circuit breaker for the 480V, three-
phase power supply, an SCR power controller for heater control, and a
480V:120V-control power transformer contained in a NEMA 4 enclosure. The
heater circuit is provided with a safety contact for over-temperature shutdown,
and fuses for short circuit protection. Over-temperature protection for the
heater is provided by a limit controller.
Each panel is internally insulated and is provided with an A/C unit and two
thermostats to protect it from the environment.
Drum Level Control
The Feedwater control system modulates the rate of feedwater flow to the
boiler to match the steam demand leaving the boiler. A relatively constant drum
level is maintained by the control system throughout the operating load range of
the boiler. Controlled steam drum level is important for two significant reasons.
§ An excessively low water flow will expose boiler tubes resulting in

overheating of the tube metal.
§ An excessively high water level will interfere with the steam-water
separating equipment in the steam drum. Water separation
becomes less effective and some water will be entrained in the
steam leaving the drum. Water is then carried over with the steam,
resulting in damage to plant equipment.
When load demand changes occur, the amount of steam required by the
turbine/process changes. The flow of feedwater to the boiler must also change
to meet the new load demands. The drum level control system provides for the
necessary balance between the turbine and the boiler.
An accurate measure of the balance between boiler fluid input and steam flow
output is steam drum level. The feedwater control system sustains this balance
by maintaining the proper fluid storage level within the boiler at all times.
Description
The feedwater control system is a control loop that, when in automatic,
maintains a balance of feedwater entering the boiler with the amount of steam
leaving the boiler. The control system also keeps the volume of boiler water
within the steam drum to an established set point level during operation.
The feedwater control system is referred to as a "three-element control

system" because three system measurements, or variables, are used to
determine the required feedwater rate to the boiler. The three elements
monitored are:
§ Drum level
§ Feedwater flow
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§ Steam flow
The three monitored elements, steam flow, steam drum level and feedwater
flow, are measured and converted into electrical signals. The signals are
transmitted as feedback control signals to the control room.
The use of three different elements provides a quick response when transients,
or changes, occur during unit operation.
The Feedwater control system is an analog control system. Drum level is the
controlled variable. Feedwater flow is the manipulated variable. Figure 20
illustrates a typical three-element control diagram.
To control swell during start-up, drum levels are maintained at a lower control
level, just above it's low water alarm setpoint, until steam flow reaches 10% of
full flow for that system.
Figure 20: Three Element Drum Level Control

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Water Level Gauge
The primary function of water gauges and indicators is to provide the operator
with a readily visible means of monitoring the water level within the steam
drums at all times.
Proper water level in steam drums is crucial during HRSG operation for the
following reasons.
§ Too low a water level in a steam drum may cause reduction and/or
loss of circulation in the tube circuits.
§ Too high a water level will reduce the effectiveness of the steam
separators and dryers in the drums causing water carry-over to the
superheating tube assemblies.
Location
The water gauge level indicator is attached to the end of each steam drum to
allow visual monitoring of the steam drum water level.
In accordance with the A.S.M.E. code for power boilers, a minimum of two (2)
steam drum level indicators must be in service on the boiler steam drum at all
times.
Description
Normal operating water level in the steam drum is approximately the centerline
of the drum. (See Tables 1, 2, and 3 for Drum Level Setpoints for the HP, IP,
and LP Drums)
The centerline of the gauge glass is located slightly below the normal water
level (NWL) to correct for sub-cooling effects during operation. The gauge
assembly consists of a steel body with flat glass faces. The tie-bar includes
upper and lower valves, which provide isolation of the water gauge for servicing
and a connection for draining. The illuminator is a device which provides an
electric lamp source for better viewing.
TABLE 1. HP DRUM LEVEL SETPOINTS
DRUM LEVEL SETPOINTS FOR 78” ID HP DRUM

START-UP SETPOINTS NORMAL OPERATING SETPOINTS
LEVEL VALUE LEVEL VALUE
HH +9 HH +9
H +7 H +7
NWL -30 NWL 0
L --32 L -9.5
LL -34 LL -34
LEVELS ARE REFERENCED TO DRUM CENTERLINE
DIMENSIONS ARE IN INCHES

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TABLE 2. IP DRUM LEVEL SETPOINTS
DRUM LEVEL SETPOINTS FOR 54” ID IP DRUM

HH +9 HH +9
H +7 H +7
NWL -18 NWL 0
L --20 L -9.5
LL -22 LL -22
LEVELS ARE REFERENCED TO DRUM CENTERLINE.
DIMENSIONS ARE IN INCHES.
TABLE 3. LP DRUM LEVEL SETPOINTS
DRUM LEVEL SETPOINTS FOR 90” ID LP DRUM

HH +19 HH +19
H +17 H +17
NWL +10 NWL +10
L -9.5 L -9.5
LL -40 LL -40
LEVELS ARE REFERENCED TO DRUM CENTERLINE.
DIMENSIONS ARE IN INCHES.
The centerline of the water gauge glass is located slightly below the normal
water level to correct for sub cooling effects during operation.
Sub cooling is a condition when the water in the lower gauge glass connection
is cooler than the water in the steam drum. The level in the water gauge will be
lower than the actual level in the drum because the density in the gauge is
greater than that of the steam drum. Placing the gauge centerline below the
drum centerline compensates for the density difference between the water
gauge and the steam drum.
The water gauge body is attached vertically to a support column, which is

connected to the water and steam sides of the steam drum through connections
provided on the end of the steam drum.
The water gauge is assembled from glass along with the necessary gaskets for
sealing against drum pressure and temperature.
The drum water level is visible in the water gauge at all times, no matter how
rapidly the water may rise or fall within the steam drum. This enables the
operator to take an accurate reading at any time during operation.

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Summary
HRSG Units use common design features as well as custom designs to match
the customer’s process needs. This manual references the triple-pressure
HRSG Unit design for most of the description details. The drawing in Figure 21
displays an example of another HRSG design.
NOTE: The chart is a reference guide to the number codes on the drawing.
No. Component No. Component

1 Condensor 30 Blowdown Tank
2 Hotwell 31 Blowdown Vent
3 Feedwater Line 32 Blowdown Drain
4 LP Economizer 33 Blowdown Return to LP Drum
5 Economizer Recirculation 34 HP System Prewarm Return Flow
6 Fuel Gas Heater Feedwater 35 LP System Prewarm Return Flow
7 Fuel Gas Heater Drain 36 Prewarm System Pump
8 Warmed Fuel Gas to GT 37 Prewarm System Heater
9 LP Feed Control Valve 38 Prewarm System LP Feed
10 LP Drum 39 Prewarm System HP Feed
11 LP Evap. Downcomers 40 Saturated Steam to HP Superheaters
12 LP Evaporator 41 1st & 2nd Stage HP Superheaters
13 LPSH Saturated Steam Feed 42 SH Desuperheater Feed, High Flow
14 LP Superheater 43 SH Desuperheater Feed, Low Flow
15 LP Steam Lead 44 HP Turbine Throttle Valve
16 LP Turbine Throttle Valve 45 HP Turbine Bypass Valve
17 LP Turbine Bypass Valve 46 HP Steam Turbine
18 LP Steam Turbine 47 Cold Reheat Lead
19 HP Evap. Feed and Recirculation. 48 Reheater
20 HP Feed Pumps 49 RH Desuperheater Feed, High Flow
21 HP Feed Control Valve 50 RH Desuperheater Feed, Low Flow
22 HP Economizer 51 RH Turbine Throttle Valve
23 GT Cooler Feedwater 52 IP Steam Turbine
24 HP & LP GT Coolers 53 Single Shaft Synchronization Clutch
25 GT to HP Separator Feed 54 Generator
26 HP Evap. Feedwater 55 GT Turbine
27 Saturation Temp. Sensing 56 Condensor Circulating Pumps
28 HP Evap. (with Orificed Inlet) 57 Air Cooling System
29 Steam Feed to HP Separator

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Figure 21: HRSG Design Sample

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Section 5: Operating Procedures and Guidelines
These procedures are intended as a guide. They include the proper operating
sequences for the HRSG and auxiliary equipment typically furnished by
ALSTOM Power.
Pre-operation
Have all HRSG auxiliary equipment lined up for operation prior to allowing flow
of the gas turbine exhaust to the HRSG.
Prior to initial operation:
§ Ensure that electrical power is available to all valve drive motor

controllers, and the stack damper motor drive.
§ Ensure that control and instrument air is available to all devices
including air-operated valves.
§ Prior to initial operation of the GT, make sure the stack damper is
open. This should be one of the permissives to start the GT.
§ All sample line valves should be closed.
§ All chemical and nitrogen feed valves should be closed.
§ All drain valves should be closed.
§ All tools and debris should be removed.
§ Ensure that all gas baffle access openings in the upper and lower
vestibule areas inside the HRSG are closed.
§ Ensure that all duct and boiler casing access doors are closed and
secured.
§ Safety valve gags should be removed and lifting levers in place.
§ Open and close the following valves to ensure that water level
gauges are reading correctly:
§ HP Drum Water Gauge Tie Bar Drain.
§ HP Drum Level Indicator Drains.
§ IP Drum Water Gauge Tie Bar Drains.
§ IP Drum Level Indicator Drains.
§ LP Drum Tie Bar Drains.
§ LP Drum Level Transmitter Drains.
§ Prior to starting the LP Economizer Recirculation Pump, the
minimum flow by-pass stop valve should be locked in the open
position.
§ The LP Economizer Recirculation System Functional Group should
be switched ON, prior to starting the gas turbine.
§ During operation the GT the LP Economizer Recirculation pump is
switched ON when the condensate temperature is below a minimum
defined value. The pump is switched OFF automatically when the
condensate temperature is above a defined value.
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Caution: The LP economizer recirculation pump must never be run with

suction and discharge valves closed. The LP economizer recirculation pump
minimum flow line stop valve must always be locked in open position. Damage
to the pump will occur if there is no water flowing through the pump.
Ensure that the following Function Groups in the DCS (Distributed Control
System) are switched on:
§ LP Economizer Recirculation System

§ LP Drum Level Control
§ IP Drum Level Control
§ HP Drum Level Control
§ HP, IP, and LP Steam Drain and Vent Valves
§ HP, IP, and LP Live Steam Temperature Control
§ Hot Reheat Steam Temperature Control
Ensure that the DCS controls for WSC/HRSG/BOP Protection Interface are in
operation.
Initial Filling
1. Prepare feedwater pumps and plant feed piping for startup.

2. Align all HRSG valves as shown under the column labeled “Start From
Cold” on Tables 1, 2, and 3 located at the end of this section.
3. Make sure all drain valves are closed.
4. Switch the Pump Function Group(s) On.
5. Before starting the HRSG feed pump, all LP, IP, and HP feed system
control valve stations should be adjusted as listed below to allow for filling of
the boiler.
§ Open HP Feedwater motor operated stop valve.
§ With HP Feedwater control valve positioned in close auto, slightly
open the HP Drum Fill control valve to allow for filling.
§ Open IP Feedwater motor operated stop valve.
§ With IP Feedwater control valve positioned in close auto, slightly
open the IP Drum Fill control valve to allow for filling.
§ Open LP Feedwater motor operated stop valve.
§ With LP Feedwater control valve positioned in close auto, slightly
open LP Drum Fill control valve to allow for filling.
§ Open LP Economizer Recirculation Pump Suction isolation valve
and lock it in the open position. Open the LP Economizer
Recirculation Pump Discharge stop valve. Open FW Preheater
Recirculation Pump Minimum Flow Line stop valve and lock it in the
open position. Open LP Economizer Recirculation Pump drain valve
to fill up the LP Economizer Recirculation Pump suction line with
water and displace air from it. Close the drain valve after 5 minutes.
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§ Ensure that HP/IP FW Pump suction stop valve is closed. Open and
lock it in the open position.
§ Ensure that the HP FW Pump Recirculation stop valve is closed.
Open and lock it in the open position.
§ Ensure that Export Water to GT Fuel Preheater stop valve is closed.
6. Start the HRSG Condensate Pump and crack open (approximately ½ turn)
the LP economizer vent valves. Fill the LP economizer and the LP
evaporator sections until the start up NWL has been cleared in the LP
Drum. DO NOT OVERFILL THE DRUM. Close the LP economizer vent
valves in each section when the air in that section has been displaced.
7. Maintain the level in the LP Drum by running the condensate pump. Drum
water level must be maintained since the HP/IP FW Pump takes suction
from the LP Drum.
8. Start the HP/IP FW Pump and crack open (approximately ½ turn) the HP
and IP Economizer vent valves. Fill the HP Economizer, IP Economizer,
and IP Evaporator until the start up NWL has been cleared in the HP and
the IP Drums. DO NOT OVERFILL THE DRUMS. Close the HP and IP
Economizer vent valves for each section when all air has been displaced
from that section.
9. After the drum fill is complete, close HP Drum Fill Control Valve, IP Drum
Fill Control Valve, and LP Drum Fill Control Valve. Place all feed system
control valve stations including the associated drum level control in AUTO
MODE.
10. All feedwater pumps can be temporarily off-line while waiting for pre-
operation equipment checks and valve alignment prior to start-up. The
HRSG is now ready to be started using the procedure for “Cold Start-up”
that follows.
Cold Start-Up
This section describes the recommended procedure for starting the HRSG from
cold conditions with no pressure in the HP, IP, and LP sections.
Align all HRSG valves as shown under the column labeled “START FROM
COLD” on Tables 1, 2, and 3 located at the end of this section.
1. Open the Stack Damper before rolling the Gas Turbine.

2. The HP Desuperheater Spraywater control valve is in “AUTO”. Open the
HP Desuperheater Spraywater stop valve.
3. The RH Desuperheater Spray Water control valve is in “AUTO”. Open the
RH Desuperheater Spraywater stop valve.
Note: Although desuperheating is not required except at peak turbine load,
it is good practice to have the control station available whenever the unit is
operating.
4. Open the HP Main Steam Outlet drain valve, HP Superheater 1 AND 2

drain valve, HP Superheater 3 Drain Valve, IP Steam Outlet drain valve,
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and LP Steam Outlet Drain Valves. Allow any condensate in these sections
to drain. After 2 minutes into start up mode, intermittently open/close the
HP Superheater 1, HP Superheater 2, and HP Superheater 3 drain valves
to clear any condensate out of the system. All HP Superheater drain valves
should be tightly closed prior to the HRSG inlet gas temperature reaching
900 degrees.
5. Open the Cold RH Drain Valves and RH Steam Outlet drain valves. Allow
any condensate to drain. Close RH drain valves after IP Steam Flow is
greater than 10%.
6. Prior to start up, reset the water level set points in the feedwater control
system to ensure that the water level in the HP, IP, and LP Drums are just
above the start up NWL. Use the HP, IP, and LP Evaporator Intermittent
blow off valves as necessary to reduce water levels.
7. Open the HP FW Inlet motor operated stop valve, IP FW Inlet motor
operated stop valve, and the LP Economizer FW Inlet motor operated stop
valve.
8. Open the HP Main Steam motor operated stop valve IP Main Steam motor
operated stop valve, and the LPSH Outlet motor operated stop valve.
During the cold start the LP steam venting will be controlled by the LPSH
Outlet Vent control valve until vacuum has been established in the steam
turbine condenser. The LP Main Steam motor operated stop valve will
remain Closed. It will be opened when the steam turbine is ready for
operation.
9. If needed, restart FW Pumps and ensure that pumps are running and all
feed system valves are lined up. ( See “START FROM COLD” on tables
1,2,and 3)
10. Start the gas turbine to allow exhaust flow to the HRSG.
11. While the steam generator is being brought up to pressure, all cold steam
piping should be gradually heated and drained of condensate. The HP
Main Steam drain valves and air operated, IP Main Steam drain valves and
air operated, and the LP Main Steam drain valves and air operated must
stay opened to insure a positive flow of steam which will reduce thermal
expansion. To warm the piping downstream of the HRSG, open the bypass
valve on the HP Main Steam non-return valve. When condenser vacuum is
established, Open the LP Main Steam motor operated stop valve and the
bypass valve on the LP Main Steam non-return valve for gradual pressure
build up and piping warm up and draining. Next, open a drain or vent
downstream of the HRSG to allow the steam from the bypass valve to warm
the piping. Ensure that all steam piping downstream of the boiler piping is
drained prior to admitting steam.
12. When a measurable HP steam flow is established (approximately 10% of
full flow), the HP steam section is “on-line” and the HP Main Steam drain
valves and air operated and the bypass on the HP NRV may be closed.
13. When a measurable IP steam flow is established (approximately 10% of full
flow), the IP steam section is “on-line” and the IP Main Steam drain valves
and air operated may be closed.

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14. When a measurable LP steam flow is established (approximately 10% of full
flow), the LP steam section is “on-line” and the LP Main Steam drain valves
and air operated and the LP NRV may be closed.
15. Reset the water level set points in the feedwater control system for the HP,
IP, and LP Drums to the normal operating water level settings.
16. Open the following cascading and continuous blowdown valves:
§ HP Drum Cascade Blowdown stop valve
§ IP Drum Continuous Blowdown stop valve
§ Blowdown flow should be controlled with the following valves:
§ HP Drum Cascade Blowdown metering valve
§ IP Drum Continuous Blowdown metering valve

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TABLE 1. VALVE ALIGNMENT: HIGH PRESSURE SECTION
VALVE DESCRIPTION START START NORMAL SECURE SECURE
FROM FROM TO TO
COLD WARM OPERATION WARM DRAIN
HP FW M/O STOP VALVE OPEN OPEN OPEN CLOSED CLOSED
HP FW CV AUTO AUTO AUTO AUTO AUTO
HP DRUM FILL CV AUTO AUTO AUTO AUTO AUTO
HP FW INLET DRAIN CLOSED CLOSED CLOSED CLOSED CLOSED
VALVES
HP FW INLET DRAIN CLOSED CLOSED CLOSED CLOSED CLOSED
VALVES
HP ECON4 VENT VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP ECON 3 DRN VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP ECON2 DRAIN VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP ECON1 DRAIN VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP DRUM CONT BD STOP CLOSED CLOSED OPEN CLOSED CLOSED
VALVE
HP CONT BD DRN VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP DRUM SAT LINE VENT CLOSED CLOSED CLOSED CLOSED CLOSED
VALVES
HP EVAP INT BO VALVE OPEN OPEN OPEN OPEN OPEN
HP EVAP BO M/O DRAIN CLOSED CLOSED CLOSED INT(***) CLOSED
VALVE
HP EVAP DRN VLVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP SH3 DRN VLVES OPEN INT CLOSED CLOSED CLOSED
HP DESH DRN VLVES CLOSED CLOSED CLOSED CLOSED CLOSED
HP STEAM OUTLET DRN OPEN OPEN OPEN OPEN OPEN
VALVE
HP STM OUTLET M/O STOP CLOSED CLOSED OPEN CLOSED CLOSED
VALVE
HP STM OUTLET NRV OPEN OPEN OPEN CLOSED CLOSED
HP SPRAYWATER POWER OPEN OPEN OPEN CLOSED CLOSED
BLOCK VLVE
HP SPRAYWATER CV AUTO AUTO AUTO AUTO AUTO
HP SPRAYWATER STOP OPEN OPEN OPEN OPEN OPEN
VLVE1
HP SH 2 DRN VLVES OPEN INT CLOSE CLOSE OPEN
Note:
Closed (*) applies to Securing to Warm Layup condition within 24 hours
immediately following GT shutdown. Open (**) applies to Securing to Warm
layup condition for period of time longer than 24 hours. Intermittent (***) applies
to maintain drum level during Warm lay-up condition for period longer than 24
hours.

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TABLE 2. VALVE ALIGNMENT: INTERMEDIATE PRESSURE/RH SECTION

FROM FROM TO TO
COLD WARM OPERATION WARM DRAIN
IP FEEDWATER M/O STOP OPEN OPEN OPEN CLOSED CLOSED

VALVE
IP FEEDWATER INLET DRN CLOSED CLOSED CLOSED CLOSED CLOSED
VLVE
IP FEEDWATER INLET CLOSED CLOSED CLOSED CLOSED CLOSED
VENT VLVE
IPECON2/1 DRN VLVES CLOSED CLOSED CLOSED CLOSED CLOSED
EXPORT WATER TO GT CLOSED CLOSED CLOSED CLOSED CLOSED
FUEL PH STOP VALVE
IP FEED CONTROL VALVE AUTO AUTO AUTO AUTO AUTO
IP DRUM FILL CONTOL AUTO AUTO AUTO AUTO AUTO
VALVE
IP DRUM CONT. BD STOP CLOSED CLOSED OPEN OPEN CLOSED
VLVE
IP DRUM CONT BD CLOSED CLOSED OPEN INT(***) CLOSED
METERING VALVE
IP EVAP. INT BO VALVE OPEN OPEN OPEN OPEN OPEN
IP EVAP BO M/O DRN CLOSED CLOSED CLOSED CLOSED CLOSED
VALVE
IP EVAP DRAIN VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
IP STEAM OUTLET A/O OPEN OPEN CLOSED CLOSED OPEN
DRAIN VALVE
IPSH OUTLET DRAIN OPEN OPEN CLOSED CLOSED OPEN
VALVE
IP STEAM OUTLET M/O OPEN OPEN OPEN CLOSED CLOSED
STOP VALVE
RHTR2 INLET DRAIN OPEN INT CLOSED CLOSED OPEN
VALVES
RHTR1 OUTLET DRAIN OPEN INT CLOSED CLOSED OPEN
VALVES
RH SPRAYWATER POWER OPEN OPEN OPEN CLOSED CLOSED
BLOCK VALVE
RH SPRAYWATER AUTO AUTO AUTO AUTO AUTO
CONTROL VLVE
RH SPRAYWATER STOP OPEN OPEN OPEN OPEN OPEN
VALVE
IP STEAM OUTLET NRV OPEN OPEN OPEN CLOSED CLOSED
VALVE
Note:
Closed (*) – applies to: Securing to Warm Lay-up condition within 24 hours
immediately following the gas turbine shutdown. Open (**) – applies to
securing to Warm Lay-up condition for period of time longer than 24 hours.
Intermittent (***) – applies to Maintain drum level during Warm lay-up condition
for period of time longer than 24 hours.

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TABLE 3. VALVE ALIGNMENT: LOW PRESSURE / GAS PATH

FROM FROM TO TO
COLD WARM OPERATI WARM DRAIN
ON
LP FEED CONTROL VALVE AUTO AUTO AUTO AUTO AUTO
LP DRUM FILL CONTROL VALVE AUTO AUTO AUTO AUTO AUTO
LP FEED DRAIN VALVE CLOSED CLOSED CLOSED CLOSED CLOSED
LP FEED M/O STOP VALVES OPEN OPEN OPEN CLOSED CLOSED
LP EVAP INTERMITTENT BO OPEN OPEN OPEN OPEN OPEN
VALVE
LP EVAP BO M/O DRAIN VALVE CLOSED CLOSED CLOSED INT(***) CLOSED
LP EVAP DRAIN VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
LP STEAM OUTLET NRV CLOSED CLOSED OPEN CLOSED CLOSED
LPSH INLET VENT VALVES CLOSED CLOSED CLOSED CLOSED CLOSED
LPSH OUTLET M/O VENT VALVE OPEN OPEN CLOSED CLOSED CLOSED
LP STEAM OUTLET A/O DRAIN OPEN OPEN CLOSED CLOSED CLOSED
VALVE
LPSH OUTLET DRAIN VALVE OPEN OPEN CLOSED CLOSED CLOSED
LP STEAM OUTLET M/O STOP CLOSED CLOSED OPEN CLOSED CLOSED
VALVE
Note:
Closed (*) – applies to Securing to Warm Lay-up condition within 24 hours
immediately following the gas turbine shutdown. Open (**) – applies to
securing to warm lay-up condition for period of time longer than 24 hours.
Intermittent (***) – applies to Maintain Drum Level during warm lay-up condition
for period of time longer than 24 hours. In addition to these valve positions,
other plant conditions, such as motors and pumps, must be monitored and
integrated to the HRSG operations
Warm/Hot Start Up
This section describes the recommended procedure for starting the HRSG from
a warm/hot condition.
1. Align all HRSG valves as shown under the column labeled “START FROM
WARM” on Tables 1, 2, and 3 located previously in this section.
2. Open the Stack Damper before rolling the Gas Turbine.
3. The HP Desuperheater Spray Water control valve is in “AUTO”. Open the
HP Desuperheater Spraywater stop valve.
4. The RH Desuperheater Spray Water control valve is in “AUTO”. Open the
RH Desuperheater Spraywater stop valve.
5. Open the HP Main Steam Outlet drain valves, HP Superheater 1 drain
valve, HP Superheater 2 drain valves, HP Superheater 3 drain valves, IP
Steam Outlet drain valve, and LP Steam Outlet drain valves. Allow any
condensate in these sections to drain. After 2 minutes into start up mode,
intermittently open/close the HP Superheater 1, HP Superheater 2, and HP
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Superheater 3 drain valves to clear any condensate out of the system. All
HP Superheater drain valves should be tightly closed prior to the HRSG
inlet gas temperature reaching 900o F.
6. Intermittently open the Cold RH drain valve, and RH Steam Outlet drain
valve. Allow any condensate to drain. Close RH drain valves after IP
Steam Flow is greater than 10%.
7. Prior to start-up, reset the water level set points in the feedwater control
system to ensure that the water level in the HP, IP and LP drums are just
above the low water alarm point. Use the HP Evaporator, IP Evaporator,
and LP evaporator Intermittent Blow-off valves as necessary to reduce
water levels.
8. Open the HP Feedwater Inlet stop valve, IP Feedwater Inlet stop valve, and
the LP Economizer Feedwater Inlet stop valves.
9. Open the HP Main Steam stop valve, the IP Main Steam stop valve, and the
LP Main Steam stop valve if steam turbine is ready for steam admission. If
steam turbine is not ready, open the LP Superheater Outlet vent valve.
During the warm start, the LP steam venting will be controlled by the LP
Superheater Outlet vent control valve until vacuum is established in the
steam turbine condenser. The LP Main Steam stop valve will remain closed
until the steam turbine is ready for operation.
10. If needed, restart the feedwater pumps and ensure that pumps are running
and all feed system valves are aligned.
11. Allow gas turbine exhaust flow to the HRSG by starting the gas turbine.
12. While the steam generator is being brought up to pressure, all cold steam
piping should be gradually heated and drained of condensate. The HP
Main Steam drain valves, IP Main Steam drain valves, and the LP Main
Steam drain valves must stay opened to insure a positive flow of steam,
which will reduce thermal expansion. To warm the piping downstream of
the HRSG, open the bypass valve on the HP Main Steam non-return valve
and the bypass valve on the IP Main Steam non-return valve. When
condenser vacuum is established, close the LP Superheater Outlet vent
valve and open the LP Main Steam stop valve and the bypass valve on the
LP Main Steam non-return valve for gradual LP pressure build up and
piping warm-up and draining. Next, open a drain or vent downstream of the
HRSG to allow the steam from the bypass valve to warm the piping. Ensure
that all steam piping downstream of the boiler piping is drained prior to
admitting steam.
13. When a measurable HP steam flow is established (approximately 10% of
full flow), the HP steam section is considered “on line” and the HP Main
Steam Drain Valve may be closed.
14. When a measurable IP steam flow is established (approximately 10% of full
flow), the IP steam section is considered “on line” and the IP Main Steam
drain valves may be closed.
15. When a measurable LP steam flow is established (approximately 10% of full
flow), the LP steam section is considered “on line” and the LP Main Steam
drain valves may be closed.
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16. Reset the water level set points in the feedwater control system for the HP,
IP, and LP Drums to the normal operating water level settings.
17. Open the following cascading and continuous blowdown valves: HP Drum
Cascade Blowdown stop valve, IP Drum Continuous Blowdown stop valve
18. Blowdown flow should be controlled with the following valves: HP Drum
Cascade Blowdown metering valve, IP Drum Continuous Blowdown
metering valve
Shutdown to Drain
This section describes the recommended procedure for securing the HRSG
without nitrogen blanketing in order to drain the unit prior to performing
maintenance.
1. Prevent any gas turbine exhaust flow to the HRSG by shutting down the gas
turbine.
2. Align all HRSG valves as shown under the column labeled "SECURE TO
DRAIN" on Tables 1, 2, and 3.
3. When the associated drum pressures fall below 25 psig, open the HP Main
Steam drain valve, IP Main Steam drain valve, and the LP Main Steam
drain valve. Main steam drain valves must be opened before the
associated drum pressure falls any lower to prevent a vacuum from
developing that may cause leakage of the drum manway gaskets.
4. Open the following drain and vent valves when HP Drum pressure reaches
15 psig: HP Drum vent valves, HP Superheater 1, and HP Superheater 3
drain valves.
5. The HRSG can be drained when it is completely cooled (when vapor no
longer escapes from the vents).
6. Open the vent valves and drain valves one heat exchanger section at a time
to avoid overloading the drain discharge system downstream of the HRSG.
Shutdown to
Warm/Hot Layup
This section describes the recommended procedure for securing the HRSG to a
warm or hot lay-up condition. When the HRSG is not in service, heat and
pressure are retained in the HP, IP, and LP sections. When pressure decays to
a low level, a nitrogen cap is maintained on the drums. These measures
prevent the entry of oxygen into the HRSG reducing the potential for internal
oxidation of the pressure parts during periods when the HRSG is not in
operation.

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Procedure for short-term WARM lay-Up (< 24 hours)
1. Reduce the gas turbine exhaust flow to the HRSG by shutting down the gas
turbine.
2. Align all HRSG valves as shown under the column labeled "SECURE TO
WARM" on Tables 1, 2 and 3. Ensure that the following valves are closed:
§ HP Feedwater motor operated stop valve
§ IP Feedwater motor operated stop valve
§ LP Feedwater motor operated stop valve
§ HP Main Steam motor operated stop valve
§ IP Main Steam motor operated stop valve
§ LP Main Steam motor operated stop valve
§ HP Drum Blowdown stop valve
§ IP Drum Blowdown stop valve
3. Close the stack damper as soon as the gas turbine rotation has stopped.
4. When the HP Drum pressure falls below 25 psig, open the HP Main Steam
drain valve. The drum pressure may be allowed to decrease to atmospheric
pressure or a nitrogen blanket may be maintained.
5. When the IP Drum Pressure falls below 25 psig, open the IP main Steam
6. When the LP Drum pressure falls below 25 psig, open the LP Main Steam
Procedure For Long-Term Warm Lay-Up (> 24 HOURS)

This section describes the recommended procedures for securing the HRSG to
a warm lay-up condition using the steam sparging system and the stack
damper to maintain the boiler warm and under pressure for periods of time
longer than 24 hours.
The warm lay-up is designed to prevent waterside corrosion by preventing the

ingress of oxygen under all conditions when the boiler is not in service and to
prevent freezing of pressure parts during low ambient conditions.
Admission of sparging steam (120 psig, 400 degrees F) to the lower manifolds
of HP, IP and LP evaporators in sequence through their respective stop and
control valves may be started when drums are at the pressure below 25 psig.
Sparging steam admission rate and pressure at the lower manifold inlet will be
maintained by the sparging steam control valves.
1. Ensure that the gas turbine is down and there is no exhaust flow to the
HRSG.
2. Ensure that the stack damper is closed.
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3. Ensure that all HRSG valves are aligned as shown under the column
labeled “SECURE TO WARM” on tables 1, 2, and 3. In particular, ensure
that the following valves are closed:
§ HP Feedwater motor operated stop valve
§ IP Feedwater motor operated stop valve
§ LP Feedwater motor operated stop valve
§ HP Main Steam motor operated stop valve
§ IP Main Steam motor operated stop valve
§ LP Main Steam motor operated stop valve
§ HP Drum Cascade Blowdown stop valve
§ IP Drum Continuous Blowdown stop valve
4. With the HP Drum pressure below 25 psig and HP Evaporator Sparging
steam control valve in auto, open the HP Evaporator Sparging Steam MOV
isolation valve.
5. With the IP Drum Pressure below 25 psig, and IP Evaporator Sparging
Steam control valve in Auto, open the IP Evaporator Sparging Steam MOV
isolation valve.
6. With the LP Drum pressure below 25 psig, and LP Evaporator Sparging
Steam control valve in Auto, open the LP Evaporator Sparging Steam MOV
isolation valve.
During the use of the sparging steam system, steam drum water level should
be monitored and any alarms due to high water level should be cleared by the
use of the continuous blowdown or MOV Evaporator drain valves. It is
essential when the HRSG is prepared for restart, that all condensate be drained
from all superheaters.
The stack closure damper system is designed to limit thermal loss due to
natural convection in the stack by isolating the HRSG from the stack. The
damper may only be closed after all rotation of the gas turbine has ceased. To
limit the use of steam in the sparging system, and to minimize thermal losses,
the damper should be closed as soon as possible. The steam sparging system
alone will not maintain the HRSG above freezing at low ambient temperatures.
The damper must be used in conjunction with the steam sparging system to
keep the unit from freezing.
Warning: When the HRSG is to be brought on-line, the stack damper must be
opened prior to rotating the gas turbine. Failure to do so will result in serious
damage to both the damper and the HRSG ductwork.

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Emergency
Procedures
High Water Level

Abnormally high water levels should be avoided as it may lead to carry-over
and even priming. In the event of a high water level, there will be a high-high
drum level alarm. Proceed as follows:
1. Blowdown the steam generator until the water is approximately at the

normal level. Use the HP Intermittent Blow-Off valve, and IP Intermittent
Blow-Off valve.
2. If the high drum level alarm still appears after 2 minutes of blowdown, stop
the gas turbine exhaust.
3. Confirm closure of the HP feedwater inlet motor operated stop valve, IP
Feedwater motor operated stop valve, and the LP Feedwater motor
operated stop valve.
4. Confirm closure of the HP Steam Outlet motor operated stop valve, the IP
Steam Outlet motor operated stop valve, and the LP Steam Outlet motor
operated stop valve.
5. Open the HP Main Steam drain valve, IP Main Steam drain valve, and the
LP Main Steam drain valves and begin normal shutdown procedures.
6. Open the HP Superheater 1 drain valves and HP Superheater 3 drain
Valves until all condensate in the superheater has been drained.
7. After correcting the cause of the high water level problem, restart the gas
turbine exhaust flow to the steam generator and bring the boiler on line in
the usual manner.
8. Investigate the water condition (alkalinity and solids).

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Low Water Level

If the water level falls out of sight in the water gauge due to failure of the
feedwater supply or neglect of the operator, appropriate action should be taken
at once. The only exception is in the case of momentary fluctuations that might
occur with extraordinary changes in load. Any decision to continue to operate,
even if only for a short time at a reduced rating, would have to be made by
someone in authority, who is thoroughly familiar with the circumstances that led
to the emergency, and knows the corrective action to be taken without
damaging the boiler. In the absence of such a decision:
1. Immediately stop the gas turbine.

2. Close the HP Feedwater motor operated stop valve, IP Feedwater motor
operated stop valve, and the LP Feedwater motor operated stop valve.
3. Shut off all steam being discharged from the unit. Close the HP Main
Steam motor operated stop valve, IP Main Steam motor operated stop
valve, and the LP Main Steam motor operated stop valve.
4. Open the HP Main Steam drain valve, IP Main Steam drain valves, and the
LP Main Steam drain valve. Begin normal shut down procedures.
5. Close the HP Drum Cascade Lowdown stop valve, and the IP Drum
Continuous Blowdown stop valve. Close export water to Fuel Heater stop
valve.
6. Check all systems to determine the cause of the low water level.
7. Re-establish proper drums levels and restart the unit.
Caution: Do not attempt to add water until the steam generator has cooled
down sufficiently to where drum metal temperatures are within 100 degrees of
the feedwater temperature; otherwise, damage may result due to relatively cool
water coming in contact with heated pressure parts.
Tube Failure
1. Immediately secure the gas turbine exhaust flow.
2. If the tube failure resulted from low water in the steam generator, close the
following valves:
§ HP Feedwater Inlet motor operated stop valve.
§ IP Feedwater Inlet motor operated stop valve.
§ LP Feedwater Inlet motor operated stop valve.
§ HP Main Steam motor operated stop valve.
§ IP Main Steam motor operated stop valve.
§ IP Steam Manual stop valve.
§ LP Main Steam motor operated stop valve.
§ HP Drum Cascade Blowdown stop valve.
§ IP Drum Continuous Cascade Blowdown stop valve
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§ Export water to Fuel Heater stop valve.
3. Open the HP Main Steam drain valve, the IP Main Steam drain valves, and
the LP Main Steam drain Valves. No water should be fed to the steam
generator. (See procedure for low water level).
4. After the pressure has decreased, allow the steam generator to cool down
slowly.
Loss of Feedwater Supply

The loss of feedwater supply is a rare occurrence in a properly maintained
steam plant. However, loss of the feedwater supply can happen and it is to be
treated as an extreme emergency.
A steady persistent drop in the steam drum level indicates problems with the
feed pump, feed pump recirculationulation control, steam generator feedwater
valve control, or a tube leak. By quickly comparing system pressures and flows
with data taken at comparable loads during normal operation, the operator
should be able to identify the problem area.
§ If feedwater flow is increasing relative to steam flow and the drum

water level is still falling, a tube leak can be assumed. Secure the
gas turbine exhaust flow and proceed with tube failure emergency
procedures.
For the HP Drum, an alarm will sound when the drum water goes to the low
level (LA). At the low-low HP Drum level the gas turbine exhaust flow should
be secured.
§ The first consideration must be the protection of steam generator

pressure parts from operation with low water.
§ If the problem is with the feed pump or controls, restrict steam
generator steam flow to balance the ability of the crippled feedwater
system to maintain drum level.
§ If it is not possible to stabilize drum levels by reducing load, secure
the gas turbine exhaust flow and bottle up the steam generator,
keeping all vents closed. When the feedwater system is repaired,
restart the unit as detailed under the procedure titled “Start-up from
a warm condition”.
As is true of any emergency situation with a steam plant, events do not always
follow an orderly pattern. The procedures above may or may not fit the pattern
for every circumstance. The intent is to emphasize what should be done in
order to protect the steam generator and safely bring the plant back in
operation as soon as possible.

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HRSG Troubleshooting Chart
Indication Probable Source Probable Cause Repair Method and Preventative

Measures
1. Unable to maintain boiler water A. Tube Leak A. Slight leakage from pitting, A. Remove boiler from service at first
concentration cracking or tube seat leak opportunity. Hydro to locate leak.
Repair by welding as indicated and as
approved by insurance or State
Inspector. Determine cause of failure
and correct it.
B. Operation at normal loads should put
B. Hide-out B. Chemicals depositing out during chemical back in solution
operation at low loads
2. Sound of steam blowing in Tube leak Substantial leak from tube The same as A above plus possible tube
furnace or setting or visible from overheating as from scale or tube re-rolling
stack seat leakage
3. Steam explosion in furnace or Tube rupture Failure of tube from low water, tube Remove boiler from the line immediately.
setting followed by inability to blockage or erosion of exterior metal Inspect and determine whether tube
maintain level surface splicing or tube replacement is necessary.
4. High conductivity Solids carry-over in the High boiler water concentration, · Check for baffle leaks in steam drum
steam or high CO2 or NH3 excessive water level fluctuation, when out of service.
in boiler water. drum baffle leakage, condenser · Check for condenser leakage or boiler
leakage or deposits on scrubbers water contamination.
· Check of degasified steam sample will
indicate if CO2 or NH3 is high.
5. High gas temperature Gas bypassing heating Gas baffle leaks or dirty heating · Increase frequency of blowing.
surface or inadequate surface Inspect unit for holes in gas baffles.
heat absorption.

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Measures
6. Excessive water level Water, load, or control High boiler water concentrations. Correct condition responsible.
conditions Extreme load swings. Varying
supply pressure or control
adjustment.
7. Bowed waterwall or generating Overheating Internal deposits or low water. · Severity of bowing will determine
tubes Usually internal deposits result in extent of tube replacement.
tubes bowing away. · Internal scale will call for internal
cleaning.
8. Tube blisters Localized overheating Internal deposit · Repair by retubing, welding tube
section, or heating and driving back
blister depending upon insurance
carried or State Inspector’s approval.
· Clean internally by acid cleaning.
9. Tube swelling (extended both Overheating Internal blocking either extensive or Retube or splice in new section as per
longitudinally and circumferentially complete insurance or State Inspector’s approval.
as compared to blisters) Probe tube for block. If blockage is from
water conditions, cleaning is required.
10. Internal pitting sharp edged and Corrosion Oxygen in boiler water Depth and extent of pitting determines
covered with tube barnacles in drum need and extent of replacement.
or tubes Extensive drum pitting can be welded but
is subject to approval by both the
manufacturer and insurance carrier or
State. Source of oxygen must be located
and eliminated.
11. Internal pitting appearing as Corrosion Acid attack-breakdown of inhibitor If noted and corrected after first occurrence
porosity of metal, especially on tube during acid cleaning generally no replacement is required. This
ends. is of course subject to consideration of
individual inspector.

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Measures
12. Internal loss of metal not Corrosion Overheating resulting in breakdown of Individual inspection will determine extent
sharply defined and accompanied water into H and O2. Cause is usually of replacement. Internal cleaning and
by black iron oxide (Fe3O4) from sludge, laydown, or pluggage. correction of water conditions are
required.
13. External pitting Corrosion From corrosive ash deposit and Extent of repair must be determined by
moisture either from dewpoint or individual inspection. In an emergency,
external source such as leaking tube tubes out of high head zone can be
plugged, ensuring they are cut to vent and
to prevent differential expansion with
adjacent tubes. Proper external cleaning
can prevent out of service corrosion.
Locate and eliminate source of moisture.
If dewpoint forms in service corrosion,
take steps to raise metal temperature.

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Section 6: Inspection and Preventative Maintenance
Heat Recovery Steam Generators (HRSG) are each designed to “fit” the Gas
Turbine (GT). This establishes both the starting design points of exhaust gas
temperature and flow rate, as well as the design choices to meet efficiency
objectives. For peak GT performance, pressure loss must be limited. This is
done at design by increasing tube lengths, the number of tubes wide across the
face of the exhaust duct, or decreasing the ratio of fin density to a height able to
increase the flow area.
All these choices lead to larger boilers, to the point of practical economic limits
of size, where the increase in size does not gain an equal increase in heat
transfer. At this point there is no gain in efficiency. The result is the largest
physical boiler practical. The pressure parts are arranged in distinct sequential
temperature zones to achieve the best heat transfer rates for the designed
efficiency.
This requires special structural support. A top supported unit for a 240 MW GT
can have over 2000 tons of pressure parts attached to the frame. The choice of
serrated finned tubes spaced very closely together requires special tube
restraints and supports. Experience has shown that the frame and casing are
as important to maintain as the pressure parts are. If the structural support has
problems, the pressure parts can fail.
Mechanical Stress
The two mechanical stresses that each HRSG must handle are vibration and
the movement of pressure parts due to thermal expansion. Vibration is chiefly
due to the flow of the exhaust gas from the GT. This is a problem in the inlet
duct, where the forces are greatest. Pressure part movement can be
significant. A typical top supported unit can expand eleven inches downward
from a cold condition to full load.
Specific Structural Failures
Inlet Duct Casing

ALSTOM’s construction is an internally insulated cold outer casing made of
Carbon Steel. See Figure 22. No alloy casing is required in the Superheater
section. Casing stiffeners are attached to casing in the shop.
The internal liner is 16 gauge stainless steel or carbon steel. It protects the
ceramic fiber or mineral wool insulation from the hot gas stream. The liner has
oversized holes and is secured with studs using large inner and outer washers
that are welded to the stud. This permits the liner to expand in all directions.
The exhaust gas can cause sufficient vibration and movement from thermal
expansion to cause the studs to break. Left uncorrected, this problem can
progress and reduce efficiency. The liner may not fully protect the insulation,

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the insulation may not contain the heat transfer as designed. Broken stud
pieces may be carried in the gas path to damage tubes or SCR catalyst. Loose
liners increase vibration, which aggravates the problem. Keeping exhaust rates
within design limits prevents this.
Figure 22: Inlet Duct Casing/Liner Assembly
Tube supports and restraints

The finned tubes are held in place by passing through groups of restraints at
several levels meant to keep these tubes in relative position. See Figure 23.
The restraints are welded to support brackets. Both are subject to weld failure
due to excessive motion of tubes. This is a little problem, that if left
uncorrected, will progress and can lead to serious damage. One broken
support or restraint permits more movement, which leads to more broken
restraints, which permits more movement, until a tube failure results.

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Figure 23: Serrated Finned Tubes
Vibration Fatigue
In locations where boiler tubes are welded to support lugs, a thick edge failure
can form at the toe of the weld. This fracture is circumferential, running at right
angles to the weld. (See Figure 24)
The root cause is:
§ the vibration of the tube, caused by the steady flow of exhaust

gases,
§ along with a lug location that induces a rigid point that will
concentrate the force into a short distance.
Figure 24: Vibration Fatigue Appearance

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Maintenance Cleaning Damage
When accumulations need to be removed with force, it is possible tubes will be
gouged or dented. (See Figure 25) This point of stress will be a weak link that
eventually gives way.
Some of the most common causes are:
§ Hammering on a tube or its support lug

§ Chiseling at fused material
§ Poking and vacuuming ash/dust/debris out of tight spaces
§ Aqua-blasting
Figure 25: Maintenance Damage Appearance

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HRSG Inspection
Recommendations
HRSG “A” Inspection - General Inspection
This inspection should be coordinated with the “A” or “B” Inspection of the GT
(at intervals of approximately 8000 EOH). This inspection is primarily a visual
survey of external casing, and internal gas side mechanical parts, and the OT
evaporator Inlet header, along with other auxiliary equipment.
HRSG “C” Inspection - Detailed Inspection
Detailed Inspections should be carried out at the same time as the “C”
Inspection of GT (approximately 24,000 EOH). In addition to the visual survey
of the external casing and internal gas side mechanical parts, this inspection
includes a visual inspection of all accessible pressure parts. The visual
inspection will identify any areas of concern that require subsequent Non-
Destructive Examination (NDE).
EOH GT HRSG Duration Number of Personnel Est total

Insp. Insp. Personnel labor hours
8000 A A 2 days 5 (1 shift per 1 field service engineer 70
day) except 1 pressure part welder
scaffolding 1 craft labor (mechanic)
2 craft labor (scaffolding)
16000 B A 2 days 5 (1 shift per 1 field service engineer 70
24000 C C 4 days 6 (1 shift per 1 field service engineer 170
32000 A A 2 days 5 (1 shift per 1 field service engineer 70
40000 B A 2 days 5 (1 shift per 1 field service engineer 70
48000 C C 4 days 6 (1 shift per 1 field service engineer 170

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HRSG “A” Inspection - GENERAL INSPECTION
Inlet Duct and Boiler Casing
The following items are noted during the inspection.
§ External Casing is inspected externally to identify any areas of

significant overheating or cracking.
§ Internal Liners are inspected for severe warping, excessive loss of
stud/washer attachments, liner cracking and loss of insulation.
§ Gas Baffles are inspected for mechanical integrity.
§ Expansion Joints are inspected internally and externally.
Pressure Parts
All readily accessible pressure part components are visually inspected. Tubing
within the gas path is inspected for severe or progressive bowing, fin/tube weld
integrity and evidence of fouling, deposits or corrosion. Particular attention to
the cold end sections is recommended. Internal inspection of the LP drum
should be carried out. All headers and connecting piping within the upper and
lower vestibules should be visually inspected. All external piping and valves
should be inspected noting hanger condition and valve condition. All pressure
part casing penetrations should be inspected for evidence of cracking. The
handhole plates in the OT inlet header shall be removed and orifices shall be
checked in place with a go/nogo gage.
Stack
External and internal inspection of the stack should note mechanical integrity
and evidence of internal corrosion. Stack dampers should be inspected to verify
full open and full closed capability and evidence of vibration and wear. Stack
silencers should be inspected for mechanical integrity, warping and integrity of
fiber packing.
SCR and CO Catalyst
SCR and CO Catalyst should be inspected for mechanical integrity of supports,

erosion/corrosion of the catalyst elements and evidence of fouling or deposits
within the catalyst elements. Ammonia injection grids should be inspected for
integrity of the mechanical supports and condition of the injection nozzles. The
ammonia supply system should be inspected pursuant to the manufacturer
recommendations.

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HRSG “C” Inspection - DETAILED INSPECTION
Visual Inspection
This inspection usually includes the following:
§ LP Steam Drum and Steam/Water Separator

§ Upper and lower LP Evaporator headers adjacent to access areas
§ Upper and lower Economizer headers adjacent to access areas
§ Upper and lower LP Superheater headers adjacent to access areas
§ HP Evaporator including removal of handhole plates for OT inlet
header
§ HP Superheater, and Reheater headers
§ Downcomers, risers, connecting lines
§ Superheat and reheat piping
§ Feedwater piping
§ LP Economizer recirculationulation pump
§ RH and SH Desuperheaters
§ Removal of Orifices in OT inlet header
§ Strainers
This visual inspection is a more detailed inspection. This may require removal
of insulation and lagging in order to access drum and external piping.
The following is noted during the inspection:
§ The external surfaces, internal surfaces and associated equipment

of all drums or steam/water separators should be visually examined
for indications of cracks, erosion, corrosion, loose or broken
hangers/supports, loose or missing internals that might be indicative
of a variety of failure mechanisms and their condition documented.
§ Condition of full penetration welds and their heat affected zones,
(including longitudinal seams for those headers fabricated from
plate, girth welds, welds at tees or formed openings and end
closures).
§ Condition of selected socket welds and their heat affected zones
(including connecting pipes, vent and drain piping).
§ Selected boreholes.
§ Machined corners of manway seating surfaces.
§ The steam drum liner or baffling should be visually examined,
preferably by means of wet test, for indications of cracks.
§ The LP recirculationulation pump should be inspected pursuant to
the manufacturer recommendations.
§ The external surfaces of a header are visually examined for
indications of cracks, corrosion, erosion, swelling, exfoliation,

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discoloration, bowing, loose or broken hangers/supports that might
be indicative of a variety of failure mechanisms and their condition
documented.
§ The internal surfaces of a header and boreholes of terminal tubes
may be examined visually for indications of cracks and for
abnormalities such as excessive deposits or corrosion.
§ Attemperator liners should be inspected for erosion and cracking
utilizing a standard borescope.
NONDESTRUCTIVE EXAMINATION (NDE)
Following visual inspection additional NDE tests should be carried out in any
areas of concern. The following techniques may be used.
§ Radiograph
§ Weld Seam Etching
§ Diameter and Circumference Measurements
Borehole Examination
One examination routinely performed during a header condition assessment is

the examination of header boreholes. This examination detects the presence of
borehole cracking through the use of an oxide cleaning method, fluorescent
dye-penetrant examination and visual/dimensional inspection.
Magnetic Particle Examination
Magnetic particle examination or testing (MT) and/or wet fluorescent magnetic

particle examination (WFMT) should be used at selective locations to determine
the existence of macrocracks that may not be apparent. Surface discontinuities
and shallow subsurface discontinuities can be detected by using this method.
Circumferential seams
Inspect a number of socket welds and their heat affected zones (including
supply tubes, terminal tubes, vent and drain nozzles).
Liquid-Penetrant Examination
Liquid-penetrant examination or testing (PT) is a highly sensitive non-

destructive method for detecting discontinuities (flaws) such as cracks, pores
and porosity which are open to the surface of solid and essentially non-porous
materials.
The fluorescent-penetrant inspection (FPT) uses penetrants that fluoresce

brilliantly under ultraviolet light. The sensitivity of the fluorescent penetrant
(solvent removable) technique is considered to be very high and recommended
for areas where minute defects may be present.
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Ultrasonic Shearwave Examination
Ultrasonic examination, utilizing O° longitudinal sound waves and 45° and 60°
refracted shear waves, is extremely useful in detecting the presence of surface
and internal discontinuities or non-homogenous areas in materials. This
technique provides useful information on whether or not the crack(s) can or
should be weld repaired.
Ultrasonic Thickness Measurements
Wall thickness readings shall be taken at the dimensional test locations, on

selected elbows and bends, and where recordable indications are found.
Readings should be taken around the whole circumference of the pipe (0°, 90°,
180° and 270°) and on the outer wall in the arc of the bend on selected elbows
and bends.

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Appendix A: Worksheets
Use the following diagrams during class activities. The class activities are
structured to allow students the opportunity to reinforce learning events and
achieve each of the course objectives. Trends indicate that the learner retains
only 30% of what they hear and more than 70% of what they say or do.
1. Draw a simple process diagram of a combined cycle unit and describe the
power plant’s basic features. Describe the purpose and function of the
HRSG Unit as it relates to the combined cycle process.

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2. Given a model unit, identify the major components of an ALSTOM Power horizontal, top supported HRSG
unit. Discuss design and functionality of each component including: low pressure system, intermediate
pressure system, high pressure system, reheater, extractions, auxiliary valves, gas side flow path, safety
valves, SCR System, drum level instruments and control.

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ALSTOM Power Last Modified: 7/3/01 i

Course Objectives ................................................................................................ vi

Classroom Checklist............................................................................................ vii

Section 1: Combined Cycle Process ........................................................................1

Section 2: HRSG Fundamentals .............................................................................5

Boiler Circulation .................................................................................................14

Intermediate Pressure System ............................................................................25

Gas Side Flow Path and Components.................................................................30

Safety Valves ......................................................................................................31

Section 5: Operating Procedures and Guidelines .................................................40

Initial Filling .........................................................................................................41

Cold Start-Up ......................................................................................................42

Shutdown to Warm/Hot Layup.............................................................................49

HRSG Troubleshooting Chart..............................................................................55

ALSTOM Power Last Modified: 7/3/01 iii

Figure 1: Simple Combustion Turbine Cycle ...........................................................2

Figure 2: Combined Cycle Power Plant ...................................................................3

Figure 3: Combined Cycle Efficiency .......................................................................4

Figure 4: Combined Cycle Plant .............................................................................5

Figure 6: Latent Heat of Vaporization/Condensation................................................7

Figure 7: Sensible and Latent Heat..........................................................................7

Figure 9: Heat Transfer Loss ................................................................................12

Figure 10: Typical Temperature Profile Across Tube Wall .....................................13

Figure 13: Temperature Limitations for Typical Tube Materials..............................14

Figure 15: Circulation Schematic for Natural (Thermal) Circulation........................15

Figure 16: Density of Water to Steam vs. Pressure................................................16

Figure 18: HRSG Schematic.................................................................................20

Figure 21: HRSG Design Sample .........................................................................39

Figure 22: Inlet Duct Casing/Liner Assembly ........................................................59

Figure 23: Serrated Finned Tubes ........................................................................60

Figure 24: Vibration Fatigue Appearance..............................................................60

ALSTOM Power Last Modified: 7/3/01 v

ALSTOM Power Last Modified: 7/3/01 vi

1. Draw a simple line diagram of a Combined Cycle Power Plant.

ALSTOM Power Last Modified: 7/3/01 vii

Section 1: Combined Cycle Process

Electricity is produced using a variety of energy sources: Fossil Power, Nuclear

The process of making electricity is a series of energy conversions. A typical

§ Heat or chemical energy converted to thermal energy

In a combustion turbine power plant (simple cycle):

1. Air enters the combustion turbine compressor section where the

A simple combustion turbine cycle is shown in figure 1.

ALSTOM Power Last Modified: 7/3/01 1

Figure 1: Simple Combustion Turbine Cycle

This process of energy conversions produces electricity and waste heat. As

ALSTOM Power Last Modified: 7/3/01 2

Figure 2: Combined Cycle Power Plant

ALSTOM Power Last Modified: 7/3/01 3

The simple combustion turbine power plant (30 – 35 % efficiency) improves to a

Figure 3: Combined Cycle Efficiency

ALSTOM Power Last Modified: 7/3/01 4

Section 2: HRSG Fundamentals

Figure 4: Combined Cycle Plant

§ The addition of heat sufficient enough to raise the temperature of

To quantify the amount of heat needed a measurement system has been

Thermal capacity (specific heat) is the quantity of heat required to produce a

Another characteristic of water is that it cools slowly in the process of giving up

Enthalpy changes are a function of temperature and pressure. The steam

Steam Generation Process

Latent Heat of Fusion

Figure 5: Latent Heat of Fusion

Latent Heat of Vaporization