HRSG TRAINING

DKME

Roger Detzel

.1

Typical B&W HRSG

.2

MODULAR CONSTRUCTION CAN BE USED IN EITHER

MULTIPLE SINGLE WIDE UNITS OR MULTIPLE
MODULES WIDE WITHIN ONE SUPPORT FRAME
ARRANGEMENT USING SINGLE FLOW PATH WITH MULTIPLE MODULES

.3

ARRANGEMENT USING MULTIPLE FLOW PATHS

SINGLE MODULE WIDE

.4

B&W DESIGN FEATURES &

CONSIDERATIONS
B&W HRSGs TAKE INTO ACCOUNT THE FOLLOWING FEATURES:
1
1.
INSIDE INSULATED
2. COLD CASING
3. COLD EXTERNAL SUPPORT FRAMES AND STEEL
4. SMALL METALLIC EXPANSION JOINT BETWEEN MODULES
5
5.
SHIPPING/LIFTING FRAME IS INTEGRAL TO THE MODULE
6. RIGGING HOLES ARE PROVIDED IN THE MODULE SHIPPING/LIFTING FRAME
7. MODULE SHIPPING/LIFTING FRAMES ARE USED TO ROTATE MODULE INTO
VERTICAL ORIENTATION
8. MODULE SHIPPING/LIFTING FRAMES HAVE BOTH PERMANENT MEMBERS & TEMPORARY MEMBERS
(TYPICALLY PAINTED YELLOW)
9. THE PRESSURE PART MODULE IS DESIGNED TO BE STRUCTURALLY INDEPENDENT UNTIL THE
EXTERNAL SUPPORT FRAME MEMBERS ARE INSTALLED.
10. THE PRESSURE PART MODULE IS NOT DESIGNED TO BE A FREE STANDING STRUCTURE THAT CAN
ACCOMMODATE HIGH WIND LOADS.
LOADS IT MUST BE TEMPORARILY TIED OFF WITH CABLES UNTIL THE
FINAL SUPPORT FRAME IS INSTALLED.
11. THE MODULE, WHEN IN ITS FINAL POSITION WITHIN THE HRSG CASING, WILL EXPERIENCE FRONT
TO REAR DIFFERENTIAL TEMPERATURES WITHIN THE MODULE STRUCTURE THAT IS LEFT IN PLACE.
12. SEISMIC/WIND LOADS ARE ACCOMMODATED BY THE EXTERNAL FRAMES AND CASING - NOT BY
MODULE STEEL.
13. SUPPORTS AT BOTTOM ARE REFERRED TO AS A BASE FRAME.
.5

B&W DESIGN FEATURES & CONSIDERATIONS

14. EACH MODULE INCLUDES SEVERAL LEVELS OF VIBRATION TIES.
15. PRESSURE PART SEISMIC LOADS ARE ACCOMMODATED BY
INTER-CONNECTING PIPES BETWEEN MODULES, BUMPERS TO TOP
CASING, RISER TUBES -OR- SATURATED CONNECTING TUBES ROUTED
INTO DRUM, TOP SUPPORTS, OR BY SUPPORTS AT THE BOTTOM OF
THE MODULE.
16. TUBE VIBRATIONS CHECKED USING METHODS DEVELOPED BY
STRUTHERS THERMOFLOOD TECHNOLOGY. VIBRATION TIE LOCATIONS
ARE BASED ON THIS ANALYSIS.
17. SH MODULES:
a. ARE TOP SUPPORTED
b. THERE IS NO PERMANENT BASE FRAME
c. A TEMPORARY LIFTING/SHIPPING FRAME IS PROVIDED
d. A TEMPORARY BOTTOM SUPPORT FRAME IS USED
e. SH MODULES ARE MORE DIFFICULT TO INSTALL
18. THE FLEXIBILITY OF PIPING CONNECTING THE TOP SUPPORTED SH
MODULE TO THE BOTTOM SUPPORTED HIGH PRESSURE BOILER
MODULE MUST BE EVALUATED
EVALUATED.

SH MODULE
.6

B&W DESIGN FEATURES

CONSTRUCTABILITY FEATURES
1. LARGE, SELF CONTAINED MODULES
2. ALL MODULES ARE BOTTOM SUPPORTED DURING ERECTION
3. MINIMAL USE OF TEMPORARY STEEL DURING SHIPMENT AND ERECTION
4
4.
NO RIGHT HAND OR LEFT HAND MODULES
5. NO ANCHOR BOLTS OR UPLIFT RESTRAINTS ON PRESSURE PART MODULES
6. MAXIMUM PREFABRICATION OF CASING AND INLET FLUE PANELS INCLUDING INTEGRAL STRUCTURAL STEEL
MEMBERS
7. NO INSIDE WORK REQUIRED AT PANEL JOINTS
8. TOP STEEL DESIGNED TO SUPPORT AND ALIGN DRUMS DURING ERECTION
9. PROVISIONS MADE IN DOWNCOMER TO DRUM FIELD WELD JOINT FOR VERTICAL ADJUSTMENT
10. DRUM LIFTING REFER TO 1U MANUAL FOR LIFTING LUGS

HRSG COLD CASING

1. DESIGNED TO ACCOMMODATE A DESIGN PRESSURE OF +25" H20 IN COMBINATION WITH WIND LOADINGS
2
2.
1/4" THICK CARBON STEEL PLATE
PLATE.
3. STANDARD SPACING AND SIZE OF STIFFENERS HAVE BEEN DEVELOPED.
4. PLATE GIRDER ACTION CONSIDERED TO TRANSFER FORE & AFT WIND LOADING AND/OR EARTHQUAKE
LOADING TO FOUNDATION.
.7

B&W HRSG DESIGN CONSIDERATIONS

THE BASIC COMPONENT OF A B&W HRSG IS THE MODULE

A MODULE IS MADE UP OF FINNED HEATING SURFACE,

CONNECTING PIPING
PIPING, A SUPPORT TRUSS,
TRUSS A BASE FRAME,
FRAME
AND IS SHIPPED AS AN ASSEMBLY FROM THE SHOP.

ONCE ON SITE, THE MODULES ARE UPRIGHTED AND

PLACED ON THE FOUNDATIONS TO FORM THE CORE OF
THE HRSG.

.8

THE ADDITION OF INLET

FLUES, STACK, DRUMS,
CASING, AND
CONNECTING PIPING
ESSENTIALLY
COMPLETES THE
TRANSITION FROM
STACKS OF FINNED
TUBES TO AN HRSG.
NOTE THAT DESIGNING
SUPPORTS FOR AN
HRSG IS SIMILAR TO
DESIGNING SUPPORTS
FOR A BOTTOM
SUPPORTED FLUE.

.9

THE STANDARD MODULE IS

DESIGNED TO BE SHIPPED TO THE
FIELD WITHOUT ANY CASING
ATTACHED. THIS IS DONE TO
MAXIMIZE THE AMOUNT OF HEATING
SURFACE IN ANY SHIPPING UNIT,
UNIT
WHILE ELIMINATING THE NEED TO
DESIGN LEFT AND RIGHT HANDED
MODULES WITH CASING ATTACHED.
ADDITIONAL UNCASED MODULES
MAY BE INCLUDED FOR
APPLICATIONS WHERE THREE OR
MORE MODULES WIDE ARE
REQUIRED.
ALLOWABLE CLEARANCES AND RAIL
CAR GROSS WEIGHT LIMITS SET
THE MAXIMUM SIZE MODULE THAT
CAN BE SHIPPED
SHIPPED. KEEPING WITHIN
THE RECOMMENDED SIZES AND
WEIGHTS LISTED IN TABLE 1
TYPICALLY ALLOWS RAIL SHIPPING
TO MOST DESTINATIONS IN THE US
AND CANADA.

.10

B&W MODULE LIMITATIONS

TABLE 1
RECOMMENDED MODULE LIMITS
Maximum Weight
150 Tons
Header to Header Distance

60 Feet

Width

11 Feet 8 In

Depth (Shipping Height)

13 Feet 8 In

.11

MODULE DESIGN CONSIDERATIONS

EACH MODULE IS MADE UP OF THREE PRIMARY COMPONENTS;

1) SECTIONS OF HEATING SURFACE, 2) THE TRUSS ASSEMBLY, 3) A
SUPPORT FRAME THAT TRANSFERS THE WEIGHT OF THE
MODULE TO THE FOUNDATION.
IN ORDER TO MINIMIZE THE AMOUNT OF ENGINEERING REQUIRED,
REQUIRED THE
COMPONENTS ARE STANDARDIZED TO THE MAXIMUM AMOUNT
PRACTICAL.
THE STANDARD ORIENTATION FOR MANUFACTURING AND SHIPPING IS
WITH THE TUBES HORIZONTAL AND THE GAS INLET SURFACE FACING
DOWN.
THIS WILL BE THE POSITION CONSIDERED
WHEN NO OTHER REFERENCES ARE MADE.
ANY TIME DESIGN WORK IS DONE ON THE MODULE ASSEMBLY OR ITS
COMPONENTS, CONSIDERATION MUST BE GIVEN TO BOTH HORIZONTAL,
VERTICAL AND INTERMEDIATE ORIENTATIONS
VERTICAL,
ORIENTATIONS.

.12

THERE ARE TWO BASIC TYPES OF MODULES

1) BOTTOM
SUPPORTED
2)TOP
SUPPORTED

.13

MODULE DESIGN CONSIDERATIONS

MODULES ARE DESIGNED AS A FUNCTION OF GAS TEMPERATURE
MODULE TYPE 1:
1. THE STANDARD MODULE IS A BOTTOM SUPPORTED ARRANGEMENT USED FOR
DESIGN GAS TEMPERATURES LESS THAN OR EQUAL TO 975OF.
2. THIS BOTTOM SUPPORTED MODULE HAS ALL CARBON STEEL STRUCTURAL MEMBERS.
3 A MAJORITY OF THE SUPPORT TRUSS IS LEFT IN PLACE AFTER UPRIGHTING IN THE
3.
FIELD.
4. INTERMEDIATE TIES WHICH PROVIDE SUPPORT FOR THE TUBES TO PREVENT
BUCKLING AND FLOW INDUCED VIBRATION ARE SUPPORTED AT FOUR CORNERS FROM
THE PERMANENT TRUSS FRAME MEMBERS
MEMBERS.
5. THERE IS NO MECHANICAL CONNECTION BETWEEN THE FINNED TUBES AND THE
INTERMEDIATE TIES, ALLOWING THEM TO EXPAND INDEPENDENTLY OF THE TRUSS
MEMBERS.
6 IN ADDITION TO THE WEIGHT OF HEATING SURFACE,
6.
SURFACE THE BOTTOM SUPPORTED
MODULE IS DESIGNED TO CARRY THE WEIGHT OF A STEAM DRUM WHICH IS ALWAYS
BOTTOM SUPPORTED BY THE DOWNCOMER.
7. THE DOWNCOMER MUST BE SIZED TO ACCOMMODATE INTERNAL DESIGN PRESSURE
AND TEMPERATURE
TEMPERATURE. IT MUST ALSO BE ABLE TO RESIST COLUMN BUCKLING THAT
WILL OCCUR DUE TO THE WEIGHT OF THE DRUM.

.14

DC COLUMN CHECK USING AISC 9TH EDITION, MODIFIED FOR ELEVATED TEMPERATURE

.15

AISC NINTH EDITION ALLOWABLE COMPRESSION

.16

DOWNCOMER
VIBRATION

.17

DOWNCOMER SUPPORT LUG DESIGN

PROCEDURE
DOWNCOMER SUPPORT LUGS MAY BE
C C
CHECKED
USING
S G THE PROCEDURES
OC
S
OF ASME SECTION I CODE AS A GUIDE.

.18

SUPPORT LUG ANALYSIS

.19

THE SAME SHEAR LUG DESIGN PROCEDURES CAN BE

APPLIED TO THE SH SECTIONS SUPPORTS AT TOP STEEL

.20

MODULE TYPE 2
1. THE SECOND TYPE OF MODULE DESIGN IS A TOP SUPPORTED
ARRANGEMENT USED WHEN ENTERING GAS TEMPERATURES ARE 1800OF
OR LOWER AND THE EXITING TEMPERATURE IS 975OF OR LOWER.
2 THE TOP SUPPORTED DESIGN REQUIRES THAT THE FRONT AND SIDE
2.
PORTIONS OF THE STRUCTURAL TRUSS BE REMOVED AFTER THE
MODULE IS UPRIGHTED.
3. THE INTERMEDIATE TIES ARE THE SAME GEOMETRY AS THE LOW
TEMPERATURE MODULE, BUT ARE MADE FROM ALLOY MATERIAL
SUITABLE FOR THE GAS TEMPERATURE.

4. THE FRONT OF THE INTERMEDIATE TIE ASSEMBLY IS SUPPORTED BY

RODS FROM THE TOP HEADERS.
HEADERS

.21

MODULE TYPE 2
5. AT HIGHER GAS TEMPERATURES, A
SEPARATE SET OF RODS IS REQUIRED TO
SUPPORT EACH ELEVATION OF
INTERMEDIATE TIES.
TIES THE REAR OF THE
INTERMEDIATE TIES ARE SUPPORTED
FROM THE REAR SECTION OF THE TRUSS
THAT IS LEFT IN PLACE.
6 BECAUSE THE HIGH GAS TEMPERATURES
6.
WOULD MAKE IT IMPRACTICAL TO INCLUDE
A DOWNCOMER, THERE IS NEVER A DRUM
LOCATED OVER A TOP SUPPORTED
MODULE.
MODULE

LEFT IN PLACE

SUPPORT FOR
VIBRATION TIE

.22

MODULE ASSEMBLY (SECTIONS)

THE TYPICAL HRSG MODULE CONSISTS OF SECTION TUBES WITH 3/4 INCH HIGH FINS, AN UPPER
AND LOWER HEADER, 51 FINNED TUBES, AND TROUGH ASSEMBLIES WITH SERPENTINE BARS. IF
THE SURFACE IS BOTTOM SUPPORTED, SUPPORT LUGS ARE ALSO WELDED TO THE BOTTOM OF
THE HEADER. DURING FABRICATION AND SHIPPING, THE SECTIONS ARE SUPPORTED BY THE
HEADERS AT THE TOP AND BOTTOM AND AT THE VIBRATION TIES LOCATED AT LOCATIONS ALONG
THE LENGTH OF THE SECTIONS. ONCE THE MODULES ARE UPRIGHTED IN THE FIELD, THE WEIGHT
OF EACH SECTION IS SUPPORTED THROUGH THE LOWER HEADER FOR BOTTOM SUPPORTED
MODULES OR FROM THE CONNECTING PIPING ON TOP SUPPORTED MODULES.
THE VIBRATION TIE/HORIZONTAL RESTRAINT LOCATIONS CAN BE DESCRIBED AS MULTIPLE
TROUGH ASSEMBLIES THAT ARE
MADE FROM STRUCTURAL TUBING
AND FLAT BARS. SERPENTINE
BARS ARE MADE FROM FLAT BAR
ROLLED OR STAMPED TO SHAPE
THAT FITS AROUND THE FINNED
SECTION TUBES.

.23

MODULE ASSEMBLY
SHIPPING SUPPORT &
VIBRATION TIE/LATERAL RESTRAINT

.24

THE TROUGH ASSEMBLIES ARE WELDED TOGETHER TO FORM THE INTERMEDIATE

TIES NECESSARY FOR ELIMINATING FLOW INDUCED VIBRATION AND FOR STABILITY
AGAINST THE COMPRESSIVE LOADING ON BOTTOM SUPPORTED MODULES. THE
MAXIMUM SPACING BETWEEN INTERMEDIATE TIES IS 15 FEET.

.25

INTERMEDIATE TIES

.26

MODULE ASSEMBLY
THE SECTIONS ARE FABRICATED IN THE
HORIZONTAL POSITION USING AN ELEVATED
ASSEMBLY FRAME. THE ASSEMBLY FRAME
ALLOWS ACCESS FOR PERFORMING THE TUBE TO
HEADER WELDS FROM THE TOP AND BOTTOM OF
THE HEADERS. TOP AND BOTTOM HEADERS ARE
SECURED THE CORRECT DISTANCE APART IN THE
FIXTURE AND THE TROUGH ASSEMBLIES ARE SET
IN PLACE. TUBES ARE BROUGHT INTO POSITION
AND INSERTED IN THE BOTTOM HEADER WHICH
HAS THE DRILLED THROUGH HOLE. A FIBER
WASHER IS PLACED IN THE COUNTER BORE HOLE
OF THE UPPER HEADER AND THE TUBE IS
BROUGHT UP TIGHT AGAINST THE WASHER IN THE
COUNTER BORE. NO ADDITIONAL ALIGNMENT IS
REQUIRED AS ANY TOLERANCE IN THE TUBE
LENGTH OR HEADER IS ACCOMMODATED IN THE
THROUGH DRILLED HOLE OF THE LOWER
HEADER. THE SERPENTINE BAR IS SET IN PLACE
AND WELDED TO THE SIDE PLATES ON THE
TROUGH ASSEMBLY AND THE SECOND ROW OF
TUBES IS INSTALLED.
.27

MODULE ASSEMBLY

.28

BOTTOM HEADER

.29

SINGLE SECTION

.30

MODULE ASSEMBLY

.31

MODULE
TRUSS
DESIGN
REQUIREMENTS
.32

TRUSS ASSEMBLY
THE TRUSS ASSEMBLY ON EACH SIDE OF A MODULE
PROVIDES THE STRENGTH NECESSARY FOR
SHIPPING, HANDLING, AND UPRIGHTING. THE SIDE
TRUSSES ARE CONNECTED BY WIDE FLANGE BEAMS
AT THE TOP & BOTTOM HEADER LOCATIONS AND AT
INTERMEDIATE TIE LOCATIONS. THE SUPPORT BASE
FRAME IS ATTACHED TO THE BOTTOM END OF THE
TRUSS. THE LOWER BEAMS CARRY THE DEAD LOAD
OF THE MODULE INTO THE TRUSS WHEN IT IS LIFTED
IN THE HORIZONTAL POSITION AND ACT AS THE
SUPPORT LOCATIONS FOR SHIPPING OR STORAGE.

.33

.34

TEMPORARY STEEL AT TOP

.35

A LEFT AND RIGHT HAND TRUSS ASSEMBLY IS SUPPLIED FOR EACH MODULE.
EACH ASSEMBLY HAS TOP AND BOTTOM BEAMS WITH VERTICAL MEMBERS OF
10" X 4" X " STRUCTURAL TUBING ATTACHED BY PINNED CONNECTIONS TO GUSSET
PLATES.
CHANNEL DIAGONALS ARE WELDED TO THE GUSSETS TO FORM THE TRUSS. THE
DIAGONAL MEMBERS MUST BE REMOVED IN THE FIELD AFTER THE MODULE IS IN THE
UPRIGHT POSITION.
FOUR REINFORCED LIFTING POINTS ARE LOCATED ON EACH TRUSS ASSEMBLY,
THREE ON THE TOP BEAM WITH TWO AT THE TOP AND ONE NEAR THE BOTTOM, AND A
SINGLE LIFTING POINT AT THE TOP OF THE LOWER BEAM. THIS ALLOWS LIFTING THE
MODULE ASSEMBLY IN THE HORIZONTAL POSITION WITH THE RIGGING INSTALLED TO
SUPPORT IT VERTICALLY IF THE ERECTOR SO CHOOSES.

.36

DURING OPERATION, THE TRUSS CHORDS

OF BOTTOM SUPPORTED MODULES WILL
EXPAND UPWARD. THE HOTTER MEMBER IN
THE FRONT OF THE MODULE WILL EXPAND
MORE THAN THE ONE TO THE REAR.
FLEXIBILITY IS PROVIDED THROUGH THE
USE OF PIN CONNECTIONS BETWEEN THE
HORIZONTAL AND VERTICAL TRUSS
MEMBERS AND AT SUPPORTS FOR THE
VIBRATION TIES SHOWN TO RIGHT.

.37

MODULE STEEL WITH &

WITHOUT BRACING. NOTE
THAT T1 > T2. IF DIAGONAL
BRACING
C G IS
S LEFT IN,,
THERMAL STRESSES AND
STRAINS WILL OCCUR IN
SIDE TRUSSES.

.38

IN THE FIGURES TO THE RIGHT, THE TRUSS

ASSEMBLIES USED FOR THE TOP SUPPORTED
MODULES ARE SHOWN.
NOTE THAT ALL BUT THE TOP TRUSS CHORD
WILL BE REMOVED ONCE THE MODULE IS IN
THE UPRIGHT POSITION. NOTE ALSO THAT
THE PINNED CONNECTION WHERE THE
INTERMEDIATE TIES ARE SUPPORTED FROM
THE TOP BEAM ARE RETAINED. (SEE NEXT
SLIDE.)

.39

NOTE THAT MOST OF THE

TRUSS MEMBERS ARE
TEMPORARY MEMBERS
THAT MUST BE REMOVED
AFTER MODULE IS IN
UPRIGHT POSITION.

.40

SH MODULE

FLOW

.41

SH MODULE

FLOW

.42

Typical HRSG with module temporary shipping &

permanent support steel

.43

Typical HRSG with only module permanent support steel

.44

HRSG
ISOMETRIC
EXPLODED
VIEW

.45

ISOMETRIC
TWO MODULES
DRUM SHOWN

.46

ISOMETRIC
TWO MODULES
NO DRUM
BRACING SHOWN

.47

FIN WEIGHT

.48

SOLID FIN
WEIGHT

.49

SERRATED FIN
WEIGHT

.50

TUBE PLUS
FIN WEIGHT

.51

COMPARE Q
QUICK CHECK TO RESULTS
ON PREVIOUS PAGE

.52

VIBRATION
B&W CHECKS FINNED TUBE
VIBRATIONS USING METHODS
DEVELOPED BY STRUTHERS
THERMOFLOOD TECHNOLOGY,
A COMPANY ACQUIRED BY
B&W IN 1990.
.53

STRUTHERS VIBRATION PROCEDURE

.54

STRUTHERS VIBRATION PROCEDURE

Note: 0.0278/(12 x 144)

= .00001609

.55

VIBRATION
CHECK
FOR
L = 40 FEET

.56

VIBRATION
CHECK
FOR
L = 12 FEET

.57

HRSG BASE FRAME

THE BASE FRAME IS
USED TO TRANSFER
THE WEIGHT OF
BOTTOM SUPPORTED
MODULES (SECTION
WEIGHT & DRUM) TO
THE FOUNDATION.

THE BASE FRAME

HAS BEEN
STANDARDIZED TO
THE MAXIMUM
EXTENT POSSIBLE.

.58

BASE FRAME
THE FOLLOWING SLIDES SHOW A
STANDARD BOTTOM SUPPORTED
MODULE BASE FRAME.
IN SKETCH TO THE RIGHT, THE
TWO WIDE FLANGE BEAMS THAT
RUN FRONT TO REAR (W21X111),
(
),
CARRY THE LOAD OF INDIVIDUAL
SECTIONS WHICH ARE
SUPPORTED BY SHORT
STRUCTURAL TUBE MEMBERS.

.59

BASE FRAME MEMBER SIZES

TO SIMPLIFY DETAILS AND
STANDARDIZE CONSTRUCTION, THE
BASE FRAME MEMBER SIZES SHOWN
TO THE RIGHT SHOULD BE
CONSIDERED FOR ALL MODULES UP
TO AND INCLUDING THE MAXIMUM
MODULE WEIGHT OF 150 TONS

DRUM

ID X TH
96X8
96X7
96X6.5
96X6.0
96X5.5
96X5 0
96X5.0
72X6.5
72X6.0
72X5.5
72X5.0
72X4.5
NO DRUM

BEAM
#1
SIZE
W21X147
W21X132
W21X132
W21X122
W21X122
W21X111
W21X111
W21X101
W21X101
W21X101
W21X101
W21X62

BEAM #2 AT DESIGN TEMPERATURE SHOWN

750F
800F
850F
FLANGE
FLANGE
FLANGE
SIZE
WIDTH
SIZE
WIDTH
SIZE
WIDTH
(INCHES)
(INCHES)
(INCHES)
W18X119
11 1/4
W21X132
12 1/2
W27X178
14 1/8
W18X106
11 1/4
W18X143
11 1/4
W24X176
12 7/8
W18X106
11 1/4
W18X143
11 1/4
W24X162
13
W18X97
11 1/8
W18X130
11 1/8
W24X162
13
W16X100
10 3/8
W18X130
11 1/8
W21X166
12 3/8
W16X100
10 3/8
W18X119
11 1/4
W21X166
12 3/8
W16X89
10 3/8
W18X97
11 1/8
W21X132
12 1/2
W16X77
10 1/4
W16X100
10 3/8
W18X143
11 1/4
W16X77
10 1/4
W16X100
10 3/8
W18X130
11 1/8
W16X67
10 1/4
W16X89
10 3/8
W18X130
11 1/8
W16X67
10 1/4
W16X89
10 3/8
W18X119
11 1/4
W16X67
-

.60

BASE FRAME

.61

THE W27 X 102 BEAMS SHOWN BELOW BECOME PART OF THE STRUCTURAL FRAME OF
THE ASSEMBLED HRSG WHEN ADJACENT MODULE BASE FRAMES ARE WELDED
TOGETHER AND THE CONNECTIONS TO THE CASING PANELS ARE MADE AS SHOWN
BELOW (RIGHT).
FOUR FEET TRANSFER THE MODULE DEAD LOAD TO THE
FOUNDATION. THESE FEET DO NOT NEED TO BE BOLTED
TO THE FOUNDATION. HOWEVER, FOR UNITS MORE
THAN ONE MODULE WIDE, PROVISION FOR SIDE TO SIDE
EXPANSION MUST BE MADE.

.62

THE BASE FRAME IS CONNECTED TO THE TRUSS ASSEMBLY AND SECTIONS USING PINNED
CONNECTIONS (5L).
(5L) THE BOTTOM OF THE TRUSS ASSEMBLY CONNECTS TO POSTS,
POSTS ITEM 9,
9 AT
THE SUPPORT ASSEMBLIES 5L . THESE SLOTTED PIECES ALLOW FOR DIFFERENTIAL GROWTH
BETWEEN THE HOT TRUSS ASSEMBLY INSIDE THE HRSG AND THE COLD SUPPORT POSTS (9).

.63

THE SECTION WEIGHT IS TRANSFERRED

THROUGH PINNED CONNECTIONS TO THE
SHORT VERTICALLY ORIENTED
STRUCTURAL TUBING MEMBERS, ITEM 7.
THE BASE FRAME IS INTERNALLY
INSULATED IN THE SHOP AS SHOWN TO
RIGHT AND ON PREVIOUS SLIDE. THE
INSULATION THICKNESS ON ALL BASE
FRAMES IS 4 INCHES THICK EVEN IN
LOWER TEMPERATURE ZONES WHERE
THINNER INSULATION COULD BE
SUBSTITUTED.
ON MODULES WITH DOWNCOMERS THE
CROSS MEMBER CARRYING THE
DOWNCOMER LOAD IS SUPPORTED BY
TWO MC6 X 18 PADS WELDED TOE DOWN
TO ALLOW THE INSULATION TO BE
INSTALLED UNDER THE DOWNCOMER
SUPPORT BEAMS.

.64

LOWER
HEADER
ATTACHMENT
TO BASE
FRAME

.65

BASE FRAME MOVEMENTS FRONT VIEW

.66

BASE FRAME MOVEMENTS SIDE VIEW

.67

.68

BASE FRAME MOVEMENTS

.69

BASE FRAME
WITH LOWER
HEADERS

.70

BASE
FRAME
WITHOUT
LOWER
HEADERS
SHOWN

.71

TEMPORARY CHANNEL CONNECTING BASE

FRAME TO SHIPPING MODULE
OPTION #1

OPTION #2

.72

TEMPORARY CHANNEL (SHOULD

HAVE BEEN PAINTED YELLOW)

.73

TEMPORARY
CHANNEL
CONNECTING
BASE FRAME
TO SHIPPING
MODULE

.74

HRSG SUPPORT
STEEL

.75

DRUM & RISER TUBES

(NOTE DRUM RESTRAINTS)

.76

DRUM RESTRAINTS

.77

DRUM RESTRAINTS

.78

DRUM HUMPING MAY

BECOME AN ISSUE
FOR UNITS MORE
THAN TWO
MODULES WIDE.

.79

WHEN HUMPING IS A CONCERN, FLEXIBILITY MUST BE ADDED TO THE

SUPPLY TUBES AT THE BOTTOM OF THE MODULE AS SHOWN BELOW, LEFT.
THIS ARRANGEMENT HAS NOT YET BEEN DEVELOPED BY B&W.

ADDITIONAL FLEXIBILITY
REQUIRED

STANDARD SUPPLY TUBE

ARRANGEMENT
.80

PIPING FLEXIBILITY
B&W USES CAESAR II. TYPICAL FLEXIBILITY
CONSIDERATIONS INCLUDE RISER TUBES,,
SATURATED CONNECTING TUBES, SUPPLY
TUBES, DRAIN LINES, AND MISC PIPING.

.81

CAESAR II PIPING FLEXIBILITY

PROGRAM

.82

TYPICAL CAESAR II INPUT

.83

TYPICAL CAESAR II INPUT

.84

TYPICAL CAESAR II INPUT

.85

SAMPLE OF
CAESAR
INPUT
MODEL OF
RISER
TUBES

.86

SAMPLE OF
CAESAR II
OUTPUT

.87

SAMPLE OF
CAESAR II
STRESS
OUTPUT

.88

NOTE THAT TOP SUPPORTED SH DRAIN

LINE REQUIRES SPECIAL ROUTING AT
BOTTOM TO ENSURE ADEQUATE
FLEXIBILITY

.89

TYPICAL DETAILS
MANY SUPPORT, ATTACHMENT, AND
CONNECTION DETAILS HAVE BEEN
STANDARDIZED SO THAT THEY DO NOT HAVE TO
REDRAWN FOR EVERY CONTRACT.
EXAMPLES OF STANDARD DETAILS HAVE BEN
SHOWN ON THE NEXT SLIDE AND ON B&W
DRAWINGS 515416E
1 416E THROUGH 515429E,
1 429E
516897E, & 516898E

.90

TYPICAL DETAILS

.91

THE DRUM SHELL AND NOZZLES WALLS MUST BE

CHECKED FOR LOCALIZED STRESSES. B&W
RECOMMENDS USING THE PROCEDURES OF
WRC 107 FOR THE LOCATION SHOWN BELOW.

.92

CAESAR II WRC 107 EXAMPLE

.93

CAESAR II WRC 107 EXAMPLE INPUT

.94

CAESAR II WRC 107 EXAMPLE OUTPUT

.95

CAESAR II WRC 107 EXAMPLE OUTPUT

.96

RESTRAINT FOR MODULE WITHOUT DRUM

.97

RESTRAINTS FOR MODULE WITHOUT DRUM

LOAD TRANSFERS
FROM UPPER
PART OF MODULE
THROUGH
BUMPERS
INTO TOP CASING
AND ULTIMATELY
INTO TOP STEEL
THROUGH
DIAGONAL
BRACING

.98

RESTRAINTS FOR MODULE WITHOUT DRUM

.99

PENTHOUSE TEMPORARY SUPPORT

UPPER PENTHOUSE
IS SUPPORTED BY
DRUM. LOWER
PENTHOUSES IS
SUPPORTED BY TOP
SUPPORT FRAME
STEEL.
.100

NOTE THAT THE PENTHOUSE IS INSIDE

INSULATED BELOW THE EXPANSION
JOINT.
ABOVE THE JOINT,
JOINT THE PENTHOUSE IS
OUTSIDE INSULATED.

.101

ERECTION PROCEDURES (REFERENCE

(
DRAWING 436429E)

.102

HANDLING & LIFTING

(REFERENCE DRAWING 436429E)

.103

UNACCEPTABLE
UPRIGHTING
PROCEDURE

.104

UPRIGHTING MODULE

.105

REMOVING TEMPORARY STEEL BEFORE

SETTING MODULE IN FINAL LOCATION

.106

LOADS OF 1 SEGMENT
OR PORTION OF AN
HRSG ALONG ITS
LENGTH INCLUDE:
1. PLATFORM STEEL
1
2. DRUM
3. RISERS
4. PENTHOUSE
5 SUPPORT FRAME STEEL
5.
6. CASING PANELS
7. INSULATION
8. LINER PLATE
9 SECTION TUBES
9.
10. INTERNAL LIFTING TRUSS
11. BASE FRAME
12. SUPPLIES

.107

TOTAL WEIGHT 1 SEGMENT

.108

TOTAL WEIGHT OF

MODULE LOAD
CALCULATION
SPREAD
SHEET
(WITH WATER)

DC WT FOR
12.00
Top & Bottom HDR
HDR 1:
Top & Bottom HDR
HDR 2:
SUPPLIES/RISERS
AA:
SUPPLIES/RISERS
BB:
SUPPLIES/RISERS
CC:

ASSEMBLED MODULES

(SCH 120)
1.000

OD
MIN TH
OD
MIN TH
OD
MIN TH
OD
MIN TH
OD
MIN TH
OD
MIN TH

X
WTS
8" OD x 1"
8
1 MIN WALL
WTS
8" SCH 160
6" SCH 40
4" SCH 40
1.5" SCH 80

CENTER TO CENTER
DIST BETWEEN HEADER
S C O WEIGHT
SECTION
G
OD
MIN TH
%
FIN HGHT
FIN TH
FINS/IN
SERRATED FINS ?
FIN WT
TOT TUBE+FIN WT
# SECTIONS
# TUBES/SECTION
# MODULES WIDE
TOTAL TB/FIN WT =

56
TUBE A
2.000
0.125
9
0.75
0.049
6.0
YES
5.39
9.12
9
51
1
234.38
SIZE

T&B Header
# OF HDRS
LENGTH
MW+WW
WT/MODULE
TOT T&B HDR WT =

(KIPS)

12.00

Downcomer SIZE WT/FT

LENGTH
WT/MODULE
TOTAL DC WT =

(KIPS)

AA:(6")
4
54.55

SUPPLIES
#
MW+WW

TUBE B
2.000
0.148
9
0.750
0.049
0.0
YES
0.00
4.13
0
51
1
0.00

TUBE C
2.000
0.125
9
0.750
0.049
0.0
YES
0.00
3.73
0
51
1
0.00

HDR 1

HDR 2
18
10.52
90.56
17.15
17.15

10.52
102.48
0.00
0.00
X
151.63
151
63
60.0
9.10
9.10
BB:(4")
12
26.55

1.00

6.00

6.00

6.00

1.31

1.91

0.00

TOT SUPPLY TUBE WT

1.31

1.91

0.00

H2O WT =

28.23

AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID

1.000
10.000
1.099
6 427
6.427
0.906
6.813
0.719
5.187
0.531
3.438
0.200
1.260

AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A

34.56
78.54
25.98
32 44
32.44
21.97
36.46
13.34
21.13
6.62
9.28
0.92
1.25

METAL WT 117.59
WATER WT 34.03
METAL WT 88.42
WATER WT 14.06
14 06
METAL WT 74.76
WATER WT 15.80
METAL WT 45.39
WATER WT
9.16
METAL WT 22.53
WATER WT
4.02
METAL WT
3.12
WATER WT
0.54

TOT DC WT

151.63

LBS/FT

TOT HDR

102.48

LBS/FT

TOT HDR

90.56

LBS/FT

TOT HDR

54.55

LBS/FT

TOT HDR

26.55

LBS/FT

TOT HDR

3.66

LBS/FT

WT OF
LIFT/PERMANENT STRUCT
HEIGHT
59.00
DEPTH
10 69
10.69
WIDTH
10.52
ST10X4X1/2
WT/FT
42.05
TOT STRCT TUBE WT
20.55
5x3.5x1/2 DBL ANG
1.97
W27X102
102
2.15

FRAME MEMBERS
HORIZ WT/FT
VERT WT/FT
HORIZ L
VERT L

102
176
16.21
68

DRUM TIE STEEL

2 - W12X122'S
W18X76

244
76

W21X111
111
DC SPT ST
W16X89
200
W16X45
45
W16X45
45
INTERM TIES
BOTTOM CASING/INS
MISC
STUB COL
50
TOTAL LIFT/PERM STRUCT

SIDE CASING/INSULATION/LAGGING

LIFT/PERM ST WT/MODULE

CC:(1.5")
0
3.66

WT/MODULE

12.000
0.821
8.625
1 000
1.000
8.625
0.793
6.625
0.280
4.500
0.237
1.660
0.175

2.37
2.14
2.37
2.37
3.00
3.03
0.50
0.25
40.69

NO. MODULES

TOTAL

LENGTH/TB

**** INCLUDES WATER ****

LIFT/PERM ST WT =

2 FRAMES/MODULE
TWO SIDES PLUS TOP

51.18

3.90
1.22

HORIZ L
VERT L
CASING TH
CASING WT/FT^2

14.96
61
0.25
10.21

AVG INS DENS

INS THICKNESS
INS WT/FT^2

13
6
6.5

LINER TH
LINER WT/FT^2

0.06
2.45

5.37

TOTAL FRAME/INS/LINER WEIGHT

98.28

ASSUME 16 FT DEEP
22.37
16

14.24

40.69
40.69

TOTAL WITH CASING/INS/LAGGING/FRAME MEMBERS

LIFT STRUCTURE + DRUM+ RISERS + PH

(INCLUDES WATER)

508.1

PRESSURE PARTS ONLY(W/O DRUM OR RISERS) (INCL WATER)

263.8

PRESSURE PARTS WITH DRUM, RISERS, PH, LIFT STRUCTURE (INCL WATER)

409.8

PRESSURE PARTS + LIFT ST (W/O DRUM,RISERS OR PH)(INCL WATER)

304.5

DRUM
72

72 ID x 4.00 THICK
MOD. WIDE

TOT DR WT

LD/PER DC

95.4
95.4

AA:(6")

BB:(4")

CC:(1.5")

14

MW+WW

54.55

26.55

3.66

LENGTH/TB

10.00

10.00

10.00

WT/MODULE

0.55

3.72

0.00

TOT RISERSUPPLY TUBE

0.55

3.72

0.00

RISERS
#

(NO DRUM, RISERS, PH)

INS
THICKNESS
3.50

INS
WT/FT^2
3.79

CASNG/INS/LAGG/EXTERNL FRAME MEMBERS (NO PRESSURE PARTS)

DRUM + PH + RISERS

CASING
WT/FT^2
10.21

(INCLUDES WATER)

CASING/INSULATION/LAGGING/EXTERNAL FRAME MEMB/LIFT STRUCTURE/PH (NO PRESS

10X10X4

PENTHOUSE CASING
INS
DENSITY
13.00

PRESSURE PARTS PLUS EXTERNAL FRAME MEMBERS + LIFT STRUCTURE

(INCLUDES WATER)

402.8
144.6
98.3
105.3

TOTAL
WT
5.60

.109

TOTAL WEIGHT OF

ASSEMBLED MODULES
1
(SCH 120)
OD
X
MIN TH
1.000
WTS
OD
8" OD x 1" MIN WALL
MIN TH
WTS
OD
8" SCH 160
MIN TH
OD
6" SCH 40
MIN TH
OD
4" SCH 40
MIN TH
OD
1.5" SCH 80
MIN TH

DC WT FOR
12.00
T&B HDR
HDR 1:
T&B HDR
HDR 2:
SUPPLIES/RISERS
AA:
SUPPLIES/RISERS
BB:
SUPPLIES/RISERS
CC:

MODULE LOAD
CALCULATION
SPREAD
SHEET
(WITHOUT
WATER)

CENTER TO CENTER
DIST BETWEEN HEADER
SECTION WEIGHT
OD
MIN TH
%
FIN HGHT
FIN TH
FINS/IN
SERRATED FINS ?
FIN WT
TOT TUBE+FIN WT
# SECTIONS
# TUBES/SECTION
# MODULES WIDE
TOTAL TB/FIN WT =

56
TUBE A
2.000
0.125
9
0.75
0.049
6.0
YES
5.39
8.10
9
51
1
208.27
SIZE

T&B Header
# OF HDRS
LENGTH
MW+WW
WT/MODULE
TOT T&B HDR WT =

(KIPS)

TUBE B
2.000
0.148
9
0.750
0.049
0.0
YES
0.00
3.17
0
51
1
0.00

TUBE C
2.000
0.125
9
0.750
0.049
0.0
YES
0.00
2.71
0
51
1
0.00

HDR 1
0
10.52
88.42
0.00
0.00

HDR 2
18
10.52
74.76
14.16
14.16

**** WITHOUT WATER ****

12.000
0.821
8 625
8.625
1.000
8.625
0.793
6.625
0.280
4.500
0.465
1.660
0.465

AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID
AVG TH
AVG ID

1.000
10.000
1 099
1.099
6.427
0.906
6.813
0.719
5.187
0.531
3.438
0.200
1.260

AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A
AVG MET A
AVG INT A

34.56
78.54
25.98
25
98
32.44
21.97
36.46
13.34
21.13
6.62
9.28
0.92
1.25

METAL WT 117.59
WATER WT
0.00
METAL WT 88.42
88 42
WATER WT
0.00
METAL WT 74.76
WATER WT
0.00
METAL WT 45.39
WATER WT
0.00
METAL WT 22.53
WATER WT
0.00
METAL WT
3.12
WATER WT
0.00

TOT DC WT

117.59

TOT HDR

88 42
88.42

LBS/FT

TOT HDR

74.76

LBS/FT

TOT HDR

45.39

LBS/FT

TOT HDR

22.53

LBS/FT

TOT HDR

3.12

LBS/FT

WT OF
LIFT/PERMANENT STRUCT
HEIGHT
59 00
59.00
DEPTH
10.69
WIDTH
10.52
ST10X4X1/2
WT/FT
42.05
TOT STRCT TUBE WT
20.55
5x3.5x1/2 DBLE ANG
1.97
W27X102
102
2.15

FRAME MEMBERS
HORIZ WT/FT
VERT WT/FT
HORIZ L
VERT L

102
176
16.21
68

DRUM TIE STEEL

2 - W12X122'S
W18X76

244
76

W21X111
111
DC SPT ST
W16X89
200
W16X45
45
W16X45
45
INTERM TIES
BOT CAS/INS
MISC
STUB COL
50
TOTAL LIFT/PERM STRUCT

SIDE CASING/INSULATION/LAGGING

2.37
2.14
2 37
2.37
2.37
3.00
3.03
0.50
0.25
40.69

NO. MODULES

2 FRAMES/MODULE
TWO SIDES PLUS TOP

LBS/FT

51.18

3.90
1.22

HORIZ L
VERT L
CASING TH
CASING WT/FT^2

14.96
61
0.25
10.21

AVG INS DENS

INS THICKNESS
INS WT/FT^2

13
6
6.5

LINER TH
LINER WT/FT^2

0.06
2.45

5.37

TOTAL FRAME/INS/LINER WEIGHT

98.28

ASSUME 16 FT DEEP
22.37
16

14.24

LIFT/PERM ST WT/MODULE 40.6874

12.00

Downcomer SIZE WT/FT

LENGTH
WT/MODULE
TOTAL DC WT =

(KIPS)

AA:(6")
4
45.39

SUPPLIES
#
MW

X
117.59
60.0
7.06
7.06
BB:(4")
12
22.53

1.00
TOTAL

CC:(1.5")
0
3.12

LENGTH/TB

6.00

6.00

6.00

WT/MODULE

1.09

1.62

0.00

TOT SUPPLY TUBE WT

1.09

1.62

0.00

H2O WT =

28.22909

TOT DR WT

95.40

MOD. WIDE

1.00

LD/PER DC

40.69

TOTAL WITH CASING/INS/LAGGING/FRAME MEMBERS (NO WATER)

LIFT STRUCTURE + DRUM+ RISERS + PH

DRUM
72 ID x 4.00 THICK

LIFT/PERM ST WT =

(WITHOUT WATER)

447.5

PRESSURE PARTS ONLY(W/O DRUM OR RISERS) (W/O WATER)

232.2

PRESSURE PARTS WITH DRUM, RISERS, PH, LIFT STRUCTURE (W/O WATER)

349.3

PRESSURE PARTS + LIFT STRUCTURE

272.9

(W/O DRUM,RISERS OR PH)(W/O WATER)

95.4
PRESSURE PARTS PLUS EXTERNAL FRAME MEMBERS + LIFT STRUCTURE
AA:(6")

RISERS
#

BB:(4")

CC:(1.5")

14

MW

45.39

22.53

3.12

LENGTH/TB

10.00

10.00

10.00

WT/MODULE

0.45

3.15

0.00

TOT RISERSUPPLY TUBE

0.45

3.15

0.00

(WITHOUT WATER)

CASING/INSULATION/LAGGING/EXTERNAL FRAME MEMB/LIFT STRUCTURE/PH (NO PRESS

371.2
144.6

CASNG/INS/LAGG/EXTERNL FRAME MEMBERS (NO PRESSURE PARTS)

98.3

DRUM + PH + RISERS

76.4

(WITHOUT WATER)

10X10X4

PENTHOUSE CASING
INS
DENSITY
13.00

(NO DRUM, RISERS, PH)

INS
THICKNESS
3.50

INS
WT/FT^2
3.79

CASING
WT/FT^2
10.21

TOTAL
WT
5.60

.110

D
Drum
W
Weight
i ht C
Calculations
l l ti
FOUR MODULES WIDE
72" DRUM
TYPICAL DRUM WEIGHTS
DRUM
ID
(IN)
72.00
72.00
72.00
72.00
72.00
72.00
72.00
72.00
72.00
72.00
72 00
72.00

DRUM
TH
(IN)
6.50
6.00
5.50
5.00
4.75
4.50
4.00
3.00
2.00
1.50
1 00
1.00

SHELL
LENGTH
(FT)
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44 00
44.00

VOL
FT
489.80
449.25
409.17
369.57
349.95
330.46
291.82
215.98
142.07
105.83
70 07
70.07

HEAD
VOL
FT
72.99
66.50
60.16
53.97
50.93
47.93
42.04
30.70
19.92
14.73
9 69
9.69

METAL
WT
(LBS)
275768
252715
229972
207537
196436
185411
163592
120873
79373
59078
39084

INSUL
TH
(IN)
3.50
3.50
3.50
3.50
3.50
3.50
3.50
3.50
3.50
3.50
3 50
3.50

WATER
INSUL
LAGGING
WT
TOTAL
WT
INTERNALS
0.72
1/2 FULL 1/2 FULL
(LBS) (LBS/FT) (LBS)
(PSF)
(LBS)
(LBS)
2778
550
24200
896
42344
345986
2742
550
24200
885
42344
322885
2706
550
24200
874
42344
300095
2670
550
24200
863
42344
277614
2653
550
24200
857
42344
266489
2635
550
24200
851
42344
255441
2599
550
24200
840
42344
233576
2529
550
24200
818
42344
190764
2459
550
24200
797
42344
149172
2424
550
24200
786
42344
128831
2389
550
24200
775
42344
108792

WATER
WT
1/2 FULL
(LBS)
84687
84687
84687
84687
84687
84687
84687
84687
84687
84687
84687

TOTAL
FULL
(LBS)
388329
365229
342439
319957
308833
297785
275920
233108
191516
171175
151135

TOTAL
TOTAL
LOAD/4
LOAD/2
SUPPORTS SUPPORTS
(KIPS)
(KIPS)
86.5
173.0
80.7
161.4
75.0
150.0
69.4
138.8
66.6
133.2
63.9
127.7
58.4
116.8
47.7
95.4
37.3
74.6
32.2
64.4
27 2
27.2
54 4
54.4

.111

MORE DRUM
WEIGHT
CALCULATIONS

.112

MORE DRUM
WEIGHT
CALCULATIONS

.113

LOADS
LOADS TO BE CONSIDERED INCLUDE DEAD LOAD, PLATFORM, SEISMIC, AND WIND LOAD.
DEAD LOAD FROM BOTTOM SUPPORTED MODULES DOES NOT ENTER THE EXTERNAL SUPPORT
FRAME MEMBERS.
EXTERNAL SUPPORT FRAME MEMBERS ACCOMMODATE ONLY CASING WEIGHT, PLATFORM STEEL
WEIGHT, AND LOAD FROM EARTHQUAKE AND/OR WIND LOAD.
LOAD FROM EARTHQUAKE AND/OR WIND LOAD ARE NEVER ASSUMED TO ACT AT THE SAME TIME.
EARTHQUAKE AND WIND LOAD ARE DETERMINED PER CUSTOMER REQUIREMENT PERTAINING TO
SITE LOCATION

.114

TYPICAL HRSG
SUPPORT FRAME

.115

EARTHQUAKE
LOADING

.116

WIND LOAD

.117

PRESSURE
LOAD

.118

DESIGN OF
EXTERNAL
SUPPORT
FRAME
.119

B&W USES STAAD.Pro TO ANALYZE

SUPPORT FRAMES

.120

HRSG
SUPPORT
STEEL
SINGLE
FRAME

.121

DOUBLE WIDE

SINGLE WIDE

.122

TYPICAL STAAD MODEL

.123

STAAD INPUT

.124

STAAD INPUT

.125

STAAD INPUT

.126

STAAD INPUT

.127

STAAD INPUT

.128

STAAD INPUT

.129

STAAD INPUT

.130

TYPICAL STAAD LOAD DEFINITIONS AND

COMBINATIONS

.131

GAS SIDE
PRESSURE LOAD

VERTICAL
DEAD LOAD

SEISMIC LOAD
FROM DRUM

.132

SEISMIC LOAD
FROM DRUM

WIND LOAD

WIND LOAD

.133

STAAD RESULTS

.134

STAAD RESULTS

.135

TYPICAL STAAD OUTPUT

.136

.137

OUTRIGGER
STEEL
ARRANGEMENT
TO BE
CONSIDERED
FOR LARGE
SEISMIC LOAD

.138

OUTRIGGER
STEEL
ARRANGEMENT

.139

OUTRIGGER
STEEL
ARRANGEMENT
PLAN VIEW

.140

OUTRIGGER
STEEL

.141

LIMITATIONS
ON
STRUCTURAL
DRIFT

.142

B&W TRIES
TO LIMIT
HORIZONTAL
DISPLACEMENT
TO THE H/200
OR H/400

.143

INLET FLUE PRESSURE LOADS

FOR THE PURPOSE OF
SIZING AND SPACING
STIFFENERS, INLET
FLUE PRESSURE
LOADS ARE
CONSIDERED TO ACT
PERPENDICULAR TO
THE FLUE CASING.
DEAD LOAD & WIND
LOADS SHOULD ALSO
BE CONSIDERED.

.144

WHEN CONSIDERING
THE EFFECTS OF
PRESSURE LOADING ON
VERTICAL LOADS TO THE
FOUNDATIONS, IT IS
ASSUMED THAT
PRESSURE LOADS
ACTING ON THE TOP AND
BOTTOM CASING
CANCEL EACH OTHER
WITHIN THE SUPPORT
STRUCTURE SYSTEM.
SYSTEM

.145

WHEN CONSIDERING THE EFFECTS

OF HORIZONTAL PRESSURE
LOADING ON LOADS TO THE
FOUNDATIONS, IT IS ASSUMED THAT
UNBALANCED PRESSURE LOADS
ACTING ON THE FLUE ARE A
FUNCTION OF THE EXPANSION JOINT
OPENING.
LOAD TO FOUNDATION,
H = PR (TO LEFT) PR (TO RIGHT)
LOAD TO FOUNDATION,
V = [PR (TO LEFT) X Lv1
PR (TO RIGHT) X Lv2]/Lh
NOTE THAT DIRECTION OF
HORIZONTAL PRESSURE LOAD
ACTING ON CASING IS NOT A
FUNCTION OF DIRECTION OF GAS
FLOW.
.146

INLET FLUE ANCHORS

.147

TYPICAL STAAD MODELS OF FLUE for HRSG

DEAD LOAD + WIND LOAD

.148

CASING
STIFFENERS

.149

CASING STIFFENERS
B&W CONSIDERS LARGE PLATE DEFLECTION THEORY IN DETERMINING A
STANDARD HRSG SIDE CASING STIFFENER SPACING.
A SUSTAINED GAS SIDE PRESSURE OF 25 H20 (130PSF) WAS CONSIDERED IN
COMBINATION WITH 100 PSF WIND LOAD.
THICK CASING WAS ASSUMED.
150F WAS CONSIDERED.
A MAXIMUM STIFFENER LENGTH OF 11-6 WAS CONSIDERED.
A MAXIMUM STIFFENER SPACING OF 76 MAY BE USED.
A MINIMUM STIFFENER SIZE OF C8X11.5 MUST BE USED.
LOADINGS GREATER THAN THOSE LISTED ABOVE, CASING THICKNESS LESS
THAN , OR STIFFENER LENGTH > 11.5 FT WOULD REQUIRE ADDITIONAL
ANALYSIS TO DETERMINE STIFFENER SPACING & STIFFENER SIZE.
INLET FLUE CASING MUST BE CONSIDERED SEPARATELY.
.150

CASING STIFFENERS
NOTE END
CONNECTIONS
ARE PREENGINEERED AS
INDICATED ON
NEXT SLIDE.

.151

CASING STIFFENERS

.152

CASING STIFFENER END

CONNECTIONS

.153

INLET FLUE STIFFENER SPACING:

SEE 10K22-11R-2

.154

INLET FLUE STIFFENER SPACING EXAMPLE

.155

PLATFORM STEEL IS PROVIDED ON TOP OF THE SUPPORT FRAMES TO PROVIDE

ACCESS TO DRUMS, VALVES, AND OTHER INSTRUMENTATION AND EQUIPMENT

.156

IT MAY BE NECESSARY TO MOUNT

PLATFORMS DIRECTLY TO DRUM

.157

ACCESS TO PLATFORM STEEL MAY BE PROVIDED BY STAIRS ATTACHED TO

SIDE OF HRSG CASING PANELS AND MAIN SUPPORT FRAME.

.158

ACCESS TO PLATFORM STEEL MAY ALSO BE PROVIDED BY A SEPARATE,

SEPARATE
STAND-ALONE STAIR TOWER

.159

STAND ALONE STAIR TOWER

STAND-ALONE

.160

CUSTOMER PIPING
B&W RECOMMENDS THAT THE CUSTOMER INCORPORATE B&W
PIPING GEOMETRY IN THEIR COMPUTER ANALYSIS OF PIPING
BEYOND B&W TERMINAL POINT. THIS SIMPLIFIES B&W'S NORMAL
DESIGN PROCEDURES PERTAINING TO ACCOMMODATION OF
CUSTOMER FORCES & MOMENTS APPLIED TO THE B&W PIPING
TERMINAL LOCATION.
PREDICTED DEAD LOAD, PRESSURE, AND THERMAL STRESSES
OBTAINED FROM THE CUSTOMER'S COMPUTER ANALYSIS CAN
THEN USED BY B&W IN EVALUATING TUBE LEGS AND NOZZLE TO
HEADER OR NOZZLE TO DRUM ATTACHMENTS.
ATTACHMENTS

.161

MOVEMENTS AT
FOUNDATION

.162

B&W ASSUMES THAT THERE IS NO MOTION AT MODULE SUPPORT COLUMNS IN FORE

AND AFT DIRECTION. MOTION IS ASSUMED TO BE TAKEN UP AT EXPANSION JOINTS
BETWEEN MODULES. FOR MOTION SIDE TO SIDE DIRECTION, ASSUME CASING
TEMPERATURE = 150F.

EXAMPLE: 25.6 feet x .0063 inches/foot = 5/32

.163

EXPANSION JOINTS BETWEEN

MODULES

.164

BASE PLATE MISCELLANEOUS

EXCEPT AT THE 0-0 ANCHOR
LOCATIONS, "FLUOROGOLD" SLIDE
PLATES WILL BE PROVIDED BETWEEN
THE BASE PLATE THAT IS SHOP
ATTACHED TO THE BOTTOM OF THE
HRSG MODULE COLUMN, & THE
LOOSE BASE PLATE THAT IS SET IN
THE FOUNDATION.
IN ORDER TO OBTAIN THE FULL RATED
LOAD CAPACITY OF THE SLIDE PLATE,
ESSENTIALLY 100% BEARING
CONTACT MUST BE ACHIEVED.
AS CURRENTLY INTENDED, SETTING,
ALIGNING, LEVELING, & GROUTING
THE FOUNDATION BASE PLATES WILL
BE SET BY FOUNDATION
CONTRACTOR TO AN ESTABLISHED
DATUM ELEVATION.
.165

BASE PLATES CONTINUED

1. FOUNDATION BASE PLATES ARE ROUGH SET
TO APPROXIMATE LINE AND ELEVATION.
2. HRSG MODULES ARE ROUGH SET ON THE
FOUNDATION BASE PLATES VIA THE USE OF
HEAVY LIFT CRANES.
3. USING JACKS POSITIONED IMMEDIATELY
INBOARD OF THE MODULE COLUMNS
COLUMNS, HRSG
MODULES ARE FINAL SET TO ELEVATION, &
LOAD IS TEMPORARILY REMOVED FROM THE
FOUNDATION BASE PLATES.
4 WITH THE MODULE LOAD REMOVED,
4.
REMOVED THE
FOUNDATION BASE PLATES ARE FINAL SET
TO ACHIEVE FULL BEARING CONTACT WITH
THE SLIDE PLATES, & FINALLY GROUTED.
5. AFTER GROUT HARDENS, JACKS ARE
REMOVED, & THE MODULE SETTING ACTIVITY
IS COMPLETE.
6. IN ORDER TO FINAL SET THE FOUNDATION
BASE PLATES TO THE SLIDE PLATES, EACH
BASE PLATE SHOULD BE PROVIDED WITH
THREE (3) JACKING/LEVELING BOLTS.

.166

BASE PLATES CONTINUED

.167

BASE PLATE DESIGN CONSIDERATIONS

UPLIFT RESTRAINTS & SHEAR BARS TO BE DESIGNED TO ACCOMMODATE

FOUNDATIONS LOADS DETERMINED FOR INDIVIDUAL CONTRACTS

.168

SLIDING PADS ARE PROVIDED AT ALL BASE PLATES AWAY FROM ZERO
ZEROZERO GROWTH LINE. (SEE CLOUDED AREA BELOW.)

.169

B&W SPECIFIES TEFLON SLIDE

BEARINGS WITH:
THE REQUIRED SIZES LxW FOR
UPPER AND LOWER SLIDE PADS,
REQUIRED THICKNESS,
EXPECTED MOTIONS,
AND DESIGN TEMPERATURE.
FOLLOWING ARE SEVERAL SLIDEBEARING PROVIDERS IN UNITED
STATES:
AMSCOT 4AMSCOT.COM
SEISMIC ENERGY PRODUCTS L.P.
(FLUOROGOLD)
SEPBEARINGS.COM
LUBRITE TECHNOLOGIES (FORMERLY MERRIMAN CO.)
HANOVER, MASS.
WWW.USBFMI.COM

.170

GAS BARRIERS
GAS BARRIERS ARE NECESSARY TO PREVENT
GAS FROM BYPASSING AROUND PRESSURE
PART HEATING SURFACE. MANY TYPES OF
BARRIERS HAVE BEEN DEVELOPED AND USED
USED.
THE MAIN CONCERN IS PROVIDING A BARRIER
THAT IS NOT RIGIDLY TIED TO BOTH THE
PRESSURE PART SUPPORT STRUCTURE AND
TO THE LINER PLATE. SEE DRAWINGS 52292J
THROUGH 52296J,
52296J 52298J THROUGH 52304J,
52304J
52306J, 522207E, 522208E, AND THE FOLLOWING
SKETCHES FOR SOME EXAMPLES OF GAS
BARRIERS.
.171

GAS
BARRIERS

.172

EXAMPLE OF GAS BARRIERS

.173

EXAMPLE OF GAS BARRIERS

.174

LINER PLATES

.175

LINER PLATE ATTACHMENT

STUDS ARE SPACED
DIFFERENTLY ALONG THE
GAS FLOW PATH.

.176

.177

LINER PLATE & INSULATION REQUIREMENTS

.178

LINER PLATE & INSULATION REQUIREMENTS

.179

MISCELLANEOUS ISSUES
NOTE HOW PIPING AT TOP AND BOTTOM
OF SCR IS ROUTED
BETWEEN MODULES.

.180

NOTE INTERCONNECTING PIPING

BETWEEN MODULES

.181

SEALS AT WALL,, ROOF,, OR FLOOR

PENETRATIONS
BELOW ARE THREE ACCEPTABLE METHODS OF
SEALING AT CASING PENETRATIONS

FLEXIBLE BOX
CASING

PAGODA SEAL

NON-METALLIC
EXPANSION JOINT
.182

HRSG WITH CO CATALYST & SCR

.183

ROARK FORMULAS FOR STRESS & STRAIN

LARGE PLATE DEFLECTION THEORY

.184