European Turbine Network A.I.S.B.L.

ETN

Petroleum and natural gas industries - Waste Heat Recovery

Units for Turbine Exhaust Applications

RECOMMENDED ETN PRACTICE 544

First edition
Edited on: 26/April/2010

Contents

Foreword

Introduction

1. Scope

2. References

3. Terms and definitions

4. General
4.1 Precautions
4.2 Pressure design code
4.3 Local regulations
4.4 WHRU nomenclature

5. Proposals
5.1 Purchaser's responsibilities
5.2 Vendor's responsibilities
5.3 Documentation
5.4 Final records

6. Design considerations
6.1 Process design
6.2 Exhaust system design
6.3 Mechanical design
6.4 Combustion

7. Tubes and Fittings

 European Turbine Network A.I.S.B.L.

ETN
7.1 General
7.2 Extended surface
7.3 Materials

8. Piping, terminals and manifolds

8.1 General
8.2 Allowable movement and loads
8.3 Materials

9. Tube supports
9.1 General
9.2 Removable Bundles
9.3 Materials

10. Refractories, insulation and internal liners

10.1 General
10.2 Ceramic fibre construction
10.3 Castable construction
10.4 Pinned liner systems
10.5 Seal welded liner systems
10.6 Materials

11. Structures and appurtenances

11.1 General
11.2 Structures
11.3 Header boxes, doors and ports
11.4 Ladders, platforms and stairways
11.5 Materials

12. Stacks, ducts and breeching

12.1 General
12.2 Design considerations
12.3 Design methods
12.4 Static design
12.5 Wind-induced vibration design
12.6 Materials

13. Auxiliary equipment

13.1 Dampers and damper controls
13.2 Expansion Joints
13.3 Silencers
13.4 Burners

14. Instrument and auxiliary connections

14.1 Exhaust system
14.2 Process fluid
 European Turbine Network A.I.S.B.L.

ETN
14.3 Auxiliary connections
14.4 Access to connections

15. Shop fabrication and field assembly

15.1 General
15.2 Structural steel fabrication
15.3 Coil fabrication
15.4 Painting and galvanizing
15.5 Refractories and insulation
15.6 Field assembly

16. Inspection, examination and testing

16.1 General
16.2 Weld examination
16.3 Examination of other components
16.4 Testing

Annex A (informative) Equipment data sheets

Annex B (informative) Purchaser's checklist
Annex C (informative) Proposed shop assembly conditions
Annex D (informative) Calculation of exhaust backpressure in ducting
Annex E (informative) Combustion calculations
Annex F (informative) Heat loss calculations for insulation systems
 European Turbine Network A.I.S.B.L.

ETN
Foreword

The intent of the ETN in producing this Recommended Practice is to create a document that can be
submitted to industry and eventually be recognized as an ISO Standard. ISO (the International
Organization for Standardization) is a worldwide federation of national standards bodies (ISO
member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee
has been established has the right to be represented on that committee. International organizations,
governmental and non-governmental, in liaison with ISO, also take part in the work.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part
3. Draft International Standards adopted by the technical committees are circulated to the member
bodies for voting. Publication as an International Standard requires approval by at least 75 % of the
member bodies casting a vote.

ETN will submit this completed Recommended Practice to either Technical Committee ISO/TC 192.
Gas turbines or Technical Committee ISO/TC 67. Materials, equipment and offshore structures for
petroleum and natural gas industries with a recommendation that it be recognized as an
International Standard.

Introduction

This Recommended Practice is based on the knowledge and experience of the ETN working group.
Users of this Recommended Practice should be aware that further or differing requirements may be
needed for individual applications. This Recommended Practice is not intended to inhibit a vendor
from offering, or the purchaser from accepting, alternative equipment or engineering solutions for
the individual application. Where an alternative is offered, the vendor should identify any variations
from this Recommended Practice and provide details to the purchaser for evaluation.

In International Standards, the SI system of units is used. Where practical in this Recommended
Practice, US Customary units are included in brackets for information. A bullet (􀁺) at the beginning of
a clause or subclause indicates that either a decision is required or further information is to be
provided by the purchaser. This information should be indicated on data sheets (see examples in
annex A) or stated in the enquiry or purchase order. Decisions should be indicated on a check list (see
example in annex B).

1. Scope

1.1 This Recommended Practice provides guidelines and gives recommendations for the design,
materials, fabrication, inspection, testing, preparation for shipment, and assembly of turbine exhaust
waste heat recovery units (WHRU) for the oil and gas industries. WHRU's covered by this
Recommended Practice may be installed in either onshore or offshore installations.
1.2 Waste Heat Recovery Units covered by this Recommended Practice recover heat from the
exhaust stream of turbines into process or heat medium streams enclosed in a continuously welded,
tubular type coil bundle. Heating medium can be water, hot oils, glycols, or any number of refinery
process streams typically covered under ISO 13704.
 European Turbine Network A.I.S.B.L.

ETN
1.3 This Recommended Practice covers both unfired and fuel gas supplemental fired waste heat
recovery units.
1.4 This Recommended Practice does not apply to Heat Recovery Steam Generators (HRSG's).

6. Design considerations
6.1 Process design

General

The thermal design shall be in accordance with ISO 13704/API Std 530. Detailed thermal calculations
together with necessary comments, explanations and related base data shall be documented. The
design shall take into account the specified environmental conditions. The thermal design shall
include guaranteed performance values at all relevant process and environmental conditions.

Heat flux limits (heating media system)

Calculations of heat flux and film temperatures shall be provided. Maximum and minimum heat
output at the specified maximum and minimum gas flow conditions shall be part of the provided
design data. The calculations shall be carried out for design capacity and shall cover the heating
surfaces which have the highest heat flux and the highest film temperature. The specified maximum
allowable film temperature shall not be exceeded under any operational circumstances. The
expected fouling during operation shall be taken into account.

Design temperature
The temperature of the metal at the coldest section of the tubes shall be at least 10°C higher than
the condensing temperature of the corrosive compounds contained within the exhaust gases.
The tube metal and fin metal design temperature shall be at least 25°C higher than the highest
expected normal operating temperature for the heating medium. This must take into account the
maximum heat flow with fouling as well as any heating medium and gas flow imbalances.
Manifold design temperature shall be at least the heating medium maximum operating temperature
plus 25°C.
The maximum heating medium temperature in the coil shall be limited so that the minimum system
operating pressure remains above the heating medium vapour pressure. Calculation of the above is
required in order to prevent local boiling of the heating medium. Calculations with all relevant data
and explanations shall be carried out and documented as part of the design process. The minimum
system operating pressure shall be stated. Dry run shall be possible. The design temperature of the
tube material according to the design code shall be at least 25°C higher than the highest expected
exhaust gas temperature taken into account all applicable load cases and ambient conditions.
Exhaust gas temperature increase due to GT compressor fouling and in partial load of gas turbines
using DLE combustion systems shall be taken into account.
The thermal calculations shall specify the minimum heating medium flow through the WHRU in by-
pass mode to avoid boiling/cracking due to exhaust leakage. Possible uneven flow distribution
 European Turbine Network A.I.S.B.L.

ETN
between the tubes, uneven flow of the leaking exhaust gas and increased exhaust gas leak rates due
to normally worn sealing shall be part of this evaluation.

6.2 Exhaust system design

A 3-D- dynamic CFD analysis shall be carried out in order to identify turbulent flow, to proof that pre-
defined limits for gas speed are not exceeded; pulsation and vortexes are avoided or reduced to a
degree that will not affect the life expectancy of the equipment. In addition it must be shown that
the flow through the heat exchanger ensures full utilisation of the heating surfaces as well as to
determine the expected pressure loss in all operational modes.
The analysis shall be documented with all input and output values, graphs, comments assumptions
etc. The simulation domain shall also include the exhaust gas collector with the inlet conditions
specified at the exhaust gas collector inlet. This applies unless fully sufficient (3D CFD) gas flow data
that can be used as input for the flow calculation of downstream equipment is already available.
Recommended pressure drop on the exhaust side for all equipment downstream the exhaust
collector of aero derivative GT’s is 2000 Pa. The design pressure for the exhaust gas containing
components shall be at least 5000 Pa(g). It shall be documented that the chosen design pressure on
the exhaust gas side contains sufficient safety margin under all operational circumstances.
The pressure drop (total pressure) along the exhaust path shall be guaranteed and the method and
procedure of measurement defined.

Internal fire extinguishing system

On offshore installations flammable heating media should be avoided. In general, if flammable
heating media is specified, a complete concept (inclusive simulations) shall be developed that show
how a heat media fire resulting from sudden severe leakage in the boiler section will automatically
be detected and extinguished without risk for personal and other equipment.
Special focus is to be given to areas (like bellows) where an internal fire could enter through the
exhaust system and become present on the outside.
If internal fire extinguishing is selected, simulations shall be carried out and documented that proof
that the proposed system is able to cope with a case a described.
Exhaust ducting Exhaust ducting shall include supports, expansion bellows, inspection openings,
stiffeners and flanged joints.
Circular ducting is preferable. If square or rectangular design is used, all corners shall be formed with
a radius so that all welding will be done on the sides of the duct. Welds shall be of full pen type.
Transition cones in ducting shall be gradual and smooth.
Any inserts in the gas flow parts like vanes; flow distributers etc. should be avoided. If the results of
the CFD analysis enforce the installation of such elements to ensure sufficient flow distribution, a
detailed analysis that at least covers the following elements shall be carried out and documented:
 Natural frequency of the named equipment compared to present frequencies over the
complete GT load range.
 European Turbine Network A.I.S.B.L.

ETN
 FEM that also covers transient conditions (especially start and flame out) for the equipment
in question and fastening to the casing.

 A complete concept of how inspection, repair and possible exchange can be done with:

 For Cold Casing design the robustness in case of reduced effectiveness of insulation
(due to wear and tear) shall be evaluated. That applies especially for critical areas like
flanged connections, corners, connections of casing to structure, connections of
internals to the casing etc.
 For Hot Casing design special focus shall be given to connection of the casing to the
cold structure and stress caused by this constellation. For both casing design principles
applies that no change from cold to hot casing or vice versa along the exhaust gas path
is permitted.
No perforated liner plates shall be used in areas with severe gas flow conditions (speed, pulsation
etc) as they significantly increase the risk of quick degradation of the insulation. However, where
perforated liner plates are used, the insulation material shall be sewed into jackets.
Connection of liner plates to casing shall ensure low heat transfer, allow for free thermal expansion
of the hot side parts and be robust with respect to permanent vibration. In general, the unit should
be delivered from the place of production in as few separate items as practically possible. If the
erection concept is based on site assembling of different ducting parts, a trial fit at the place of
production shall be considered. Close and continuous supervision is required during the field
assembling process with respect to compliance with bolt tightening procedures, fitting of insulation
and liner. Pre-fabricated insulation and liner pieces shall be used under circumstances as described.

6.3 Mechanical design

General

The WHRU/HRSG consists of a casing with one or more heat exchanger(s) and will usually include a
by-pass control in the exhaust path. Necessary ducting shall be skid mounted and supplied as
packaged units including necessary expansion bellows for connection to exhaust ducting.
A circular design of exhaust channels with possibility for free thermal expansion is preferred. A stress
analyses using Finite Element Method (FEM) shall be part of the design work. This in order to verify
that stress levels in all construction elements/details are within predefined acceptance levels. These
analyses shall cover both static/normal operation and transient cases such as start-up and shut-down
and ambient conditions. In addition, results from the dynamic 3-D CFD analysis shall be used as input
in order to verify that the frequency of gas pulsations and vortexes are in sufficient distance to the
natural frequency of the equipment or lead to pulsating stress levels that reduce the life expectancy
of components. This applies for all operational conditions and load levels.
Special attention shall be paid to all stress risers and stress concentration points like:
• corners
• thickness changes (e.g. flanges)
• equipment mounted to the casing (e.g. lifting lugs, stiffeners, tube hangers)
 European Turbine Network A.I.S.B.L.

ETN
• penetrations
The resonance frequency of the equipment shall be above 40 Hz (to be confirmed by test). The
possibility for combined creep and thermal fatigue interaction shall be considered in material
selection and general design. A typical design life shall be indicated for the selected material and
operating condition.
Easy access and inspection of the inside of the exhaust gas path shall be possible. A concept for this,
taking into account all tasks that can be necessary during the lifetime of the equipment and related
material handling, shall be developed during the design process and documented.
Exhaust systems shall be designed for modular replacement. Components that by experience may
need to be replaced or maintained shall have a design which allow for such operation, i.e. sufficient
access, lifting lugs and transportation route.
On floaters, modular replacement should preferably be done without the use of platform crane.
These components shall be included in “Material handling report”. Components to be considered
under this category are expansion bellows, silencers, diverter valves, gears and actuators.

Exhaust collector

The exhaust collector is usually part of the gas turbine package. The exhaust collector shall be
designed for low internal pressure drop and the flow path shall be optimized and documented based
on dynamic 3-D CFD modelling. The design shall aim to ensure that the flow at the outlet is even
distributed and to the degree possible free of swirls and pulsation.
The flow at the exit flange of the collector shall be documented based on detailed analysis of the
internal flow. That includes complete information about speed distribution and direction for a
sufficient tight grid representing the collector exit opening, swirls, pulsations and any other flow
character that might be relevant for the design of the downstream equipment.
The analysis named shall be performed for the highest and lowest possible GT load and for two load
point inbetween.
The mechanical design shall be verified and optimized by using of the FEM. This analysis shall not
only cover steady state but also transient conditions.
The outlet flange of the exhaust collector is usually the boundary limit between the gas turbine
package and the WHRU/HRSG package. Package delivery of a WHRU/HRSG shall include the bellow
that connects both packages as well as bolts and gaskets needed for connection to the exhaust
collector.

Heat exchanger (WHRU)

The WHRU shall be of forced circulation type. Serpentine design or circular coil design for the tube
coil is acceptable. Tube thickness shall be calculated according to ISO 13704/API Std 530. The tubes
shall be of all butt welded construction. Where bends are used these shall be butt weld return bends.
If cold bending of tubes is applied, admissible limit of thinning shall be according to TEMA RCB 2.31.
Tube corrosion allowance shall be according to ISO 13705/ API Std 560.
 European Turbine Network A.I.S.B.L.

ETN
The recommended pressure drop on the heating medium side is 1 bar. The heater shall be
completely drainable to the dump tank in the erected position. All low points shall be equipped with
a drain nozzle and each high spot shall have a vent nozzle. This requirement may be omitted when
the heat transfer medium main inlet and outlet is placed at the heater low and high points.
If the requirement for drain and vent nozzles at all high/low points cannot be fulfilled due to the
specific design, a concept for drain and vent shall be presented. Drain nozzle nominal size shall not
be less than DN 40, vent nozzles not less than DN 25.
Due consideration shall be given to the effects of thermal expansion. The design of the tube coil shall
allow for easy detection of leakages. A concept for easy repair of leakages shall be developed and
presented as part of the design work.
The tube configuration must ensure effective clearance of pockets of air or gas during purging.
The tubes shall have welded fins. For serpentine design it shall be possible to remove a serpentine
and plug.
Fatigue and creep analysis shall be performed for the selected material and documented.

Boiler (HRSG)

The boiler and auxiliary installations shall be designed, manufactured, inspected, tested and
documented in accordance with EN12952.
The conventional drum type boiler is the preferred design. The use of OTSG boiler design
requires Buyers written approval and may be acceptable depending on the actual circumstances and
operational criteria’s.
The design work shall include calculations that prove flow stability in the tubes of the evaporating
section of the boiler under all operational circumstances.
The HRSG described here is of drum type boiler design. The unit shall include beside other necessary
equipment economizer, evaporator, superheater, steam drum with steam separator, blow-down
drum and water treatment systems like deaerator, condensate polishing, water monitoring and
conditioning as applicable for technology chosen.
The superheater shall be divided into two sections with a de-superheater in between for steam
temperature control.
A dynamic stability analysis to verify steam drum performance and stability of the evaporating
process in the boiler for every applicable load shall be part of the design work.
Also all calculations necessary to predict and guarantee the possible turn-down of the boiler whilst
the gas turbine is running at maximal load shall be carried out.
Fully dimensioned detail drawings showing the construction of the pressure parts to be welded and
copies of all associated welding procedure specifications shall be transmitted to the Purchaser for
comments / acceptance.
Oxygen-acetylene welding method shall not be utilized.
The longitudinal welds of adjacent strakes shall be staggered equivalent to strake plate thickness or
100 mm minimum.
 European Turbine Network A.I.S.B.L.

ETN
Austenitic materials shall not be welded to ferritic materials for parts of the boiler subject to elevated
operating temperature i.e. above 50 °C.
All attachment welds on drums and headers shall be continuous. The use of backing rings is not
accepted. Purging of welds is not accepted.
All pressure part gaskets subject to final hydro test pressure shall be renewed after the test.
Boiler drums with inside diameter 700 mm and larger shall have manhole in each end.
Access openings to boiler air and gas sides shall have a clear width of diameter 600 mm alternatively
600 x 600 mm square. Location shall be thoroughly chosen with respect to all possible tasks these
openings might be used for.
It shall be possible to perform visual inspection of all WHRU/HRSG tubes and supports. Access to
header boxes shall be provided.
Access openings in drums shall have a clear width of 320 x 420 mm. The manhole and the man hole
lid gasket surfaces shall be machined plane and have a surface Rz = 40 mm, lathe cut. When the man
hole lid is mounted in correct position without gasket, gap between the manhole and the man hole
lid gasket surfaces shall not exceed 0,25 mm. Access openings in drums shall have gaskets of the
spirally wound stainless steel / graphite type.
The steam boiler shall be furnished with two (2) feed water pumps with a capacity of 100% each at
minimum.
Direct spring loaded safety valves shall be of the full lift type. Direct spring loaded safety valves shall
have DN 80 inlet maximum.

Bolting and gaskets

* *Bolts shall be able to resist repetitive stress variations due to thermal effects. Bolts and nuts shall
be in accordance with ASTM 193 B7 / A194 2H (Cr Mo).
If the exhaust temperature can exceed 450°C tension bolts are mandatory for all ductwork
connections both for hot casing and cold casing design.
Calculations that prove that pretension is maintained whilst allowed stress levels are not exceeded
under any circumstances including transient conditions, insulation loss in cold casing design and
environmental conditions shall be part of the design. The gasket material shall not be part of the
flange pretension system.
An installation procedure shall be presented which specifies the appliance of high temperature anti
seizure compound, a sequence of bolt tightening and torques to be used.

Support of ducting

Supports shall be provided at each end of horizontal ducting sections and at midpoints as required.
One end support shall be anchored whilst the others are free to move on sliding pads or small rollers.
Support points, stiffening plates, guiding etc. shall have doubling plate when welded directly to the
exhaust duct.
 European Turbine Network A.I.S.B.L.

ETN
Local stress levels shall be verified by FEM analysis which has to include transient conditions.
The sliding supports shall be nickel-based high temperature bearing material and heat shielded to
protect the bearing material and the structural steel.
Spring supports or equivalent shall be provided to prevent lifting of the duct due to wind loads as
specified in the environmental conditions.

Stiffeners

Flat rectangular sections must be stiffened, such that cyclic stresses are kept below the maximum
allowable cyclic stress for the ducting material. The design of the stiffeners shall take into account
thermal expansion and temperature gradients in normal operation and transition cases like start-up
and shut-down.
Outer un-insulated outlet duct/nozzle shall have spiral welded stiffening flanges to avoid harmonic
wind pulsation.

Flanged joints

All sections shall be joined using flanged and bolted connections.

Supports of WHRU/HRSG

The WHRU/HRSG package shall have necessary steelwork to support the package independently of
the gas turbine package.
The unit shall be equipped with certified lifting lugs, lifting rings or equivalent lifting devices.
The WHRU/HRSG casing shall have internal support points for lifting beam removal of tube
serpentines.
The units shall have necessary platforms and ladders required for operation and maintenance. Two
escape routes may be required with one set of ladders for each route. Platforms and ladders shall not
be mounted to pressure parts.

7.3 Materials

The tubes shall be seamless. For metal design temperature below 450 °C tubes shall be to ASTM
A106 Grade B medium--carbon steel. For metal design temperatures between 450°C and 600 °C
tubes shall be low alloy steel to ASTM A335 P11, A213 T11 or similar. For metal design temperatures
above 600 °C tubes shall be alloy steels. Tube wall thickness design shall be in accordance with ISO
13704/API Std 530.
Where the calculated fin-tip temperature does not exceed 450 °C carbon steel fins may be used.
Between 450°C and 600°C the fins shall be of 5 CR - 0.5 Mo. For temperatures above 600°C suitability
with respect to production and proven long term performance shall be documented for the chosen
 European Turbine Network A.I.S.B.L.

ETN
Add Labels
material. Design life for fins shall be evaluated according to API RP 579.
https://EuropeanT 295596 ES

8. Piping, terminals and manifolds

8.1 General

Headers shall be designed and fabricated according to ASME B31.3 and ASME B 16.5.
The headers nozzles should preferably be of extruded or forged type avoiding welding directly to the
header that cannot be 100 % volumetric inspected. Tube stubs or Nippolets can alternatively be
used. Stub in weld should be avoided.
Headers shall be designed to give a uniform flow distribution to all tubes. The headers shall be sized
so that the dynamic head loss is not more than 5% of the individual tube pressure drop.
Headers shall be designed to allow for full expansion of tubes and permit accessibility for
maintenance and for welding. Sufficient length must be allowed on tubes in headers to permit
cutting and re-welding of tubes.

9. Tube supports
9.1 General

The tube support must be capable of supporting the weight of the tubes filled with heating medium
fluid as well as withstanding stresses resulting from thermal expansion. Natural frequency analysis
has to include normal operation of the heat exchanger as well as dry run at all GT load levels.
Tubes shall be supported such that cyclic stresses will be kept well below the maximum allowable
cyclic stress value for the tubing material. The tube support design shall be fretting free. The tube
support shall not be fastened directly on the tubes. When tubes are supported by the fins, each
support shall rest on at least 5 fins at each support point.

10. Refractories, insulation and internal liners

10.2 Ceramic fibre construction

Care must be taken to surface temperature with regard to personnel protection and area
classification. Possible degradation of insulation material over time is to be taken into account.
Maximum surface temperature shall be stated.
If internal insulation is used, insulation material sewed into jackets combined with internal lining
shall be used.
Due considerations shall be given to the design of lining fasteners with respect to mechanical
durability the need for free expansion of the liner plates in all directions.
Insulation material shall comply with all applicable HSE requirements. In addition, the material shall
not only be suitable for all expected temperatures but also able to withstand permanent severe
 European Turbine Network A.I.S.B.L.

ETN
vibration. Integrity and function of the insulation material shall not depend on any sort of “glue”
between the fibres. Function and life expectancy of the material shall not be influenced by humidity.
Insulation material shall be attached to the casing in a way that ensures to hold it in place during
lifetime of the equipment and that safely and permanently avoids thermal bridges.
Surfaces that can be reached from work areas, ladders, stairs or other passageways shall not have a
temperature higher than +70 °C during the whole expected lifetime of the equipment. However,
design temperatures of the chosen material in combination with marine atmosphere may require
lower temperatures on outside surfaces.
A guaranteed a “not to exceed” temperature on the outside of the exhaust gas containing equipment
shall be specified. Verification measurements shall be carried out after a certain time in operation
(earliest when the equipment has been in normal regular operation for at least for 3 months).

11. Structures and appurtenances

11.3 Header boxes, doors and ports

The exhaust ducts and bypass ducts shall be equipped with an adequate number of manholes and
inspection openings to provide access to all parts of the package.
Due consideration shall be given localisation of access doors with respect to good access from
outside. As access doors represent an interruption of the insulation and cladding and thereby a
potential weak point with respect to mechanical durability, they should not be placed in areas with
the most severe gas flow conditions.
Access doors for the exhaust gas side shall have a free circular opening of at least 600 mm diameter.
The doors of the inspection openings shall be hinged Jackets over and around manholes shall be
reinforced with a metal grid for higher resistance against mechanical forces. Manhole jackets shall be
fastened by bolt system and easily removable.

12. Stacks, ducts and breeching

12.1 General

The ducting includes all gas turbine exhaust ducts, the HRSG casing, the sections for the auxiliary
firing burners, and the ducts and transition sections as far as the stack.
The general shape of the exhaust duct should initially be designed for good aerodynamic
performance of the exhaust flue gas within the exhaust structure. Some factors that should be
considered in the aerodynamic design process are:
 Pressure loss through the exhaust stack.
 Prevention of separated flow regions.
 Uniform velocity profile (prevention of high velocity flow regions).
 Minimising vortex generation and interaction.
 Fluid excitation frequencies for use in dynamic structural design.
 European Turbine Network A.I.S.B.L.

ETN
The suitable use of analytical methods such as Computational Fluid Dynamics (CFD) can have
significant benefit in the aerodynamic design of an exhaust system due the complex flow structures
that are typically present. CFD can be used to evaluate designs, identify regions and methods for
design improvement, provide loadings for structural design and assessment, and quantify the
performance of an exhaust system during the design process.

The structural design of the duct should consider several in service load cases, including dead weight
loads, external wind loading, internal pressure loading (static loading under various operating
conditions), internal dynamic pressure loading (fluctuation pressures and could excite panel and duct
structural modes), seismic and thermal loading. Therefore in addition to considering static load cases,
the dynamic behaviour of the duct needs to be assessto minimise the likelihood of damage caused by
vibration. This requires ducting to be specifically designed to minimise drumming from flow induced
vibration (when exposed to gas turbine exhaust flow, over the complete flow range) and structurally
transmitted vibration. Effective vibration isolation from the gas turbine is particularly essential.

12.2 Design considerations

12.2.1 Aerodynamic Design of Flue Gas Path

Some good practice guidelines for aerodynamic design of the flue gas path are given below:
 Abrupt changes in flue gas flow direction should be avoided.
 Sharp angled (mitred) corners should be avoided.
 The average flue gas velocity should be limited to a maximum of 30 m/s.
 Regions of local high velocity flow should be avoided. These typically occur in bends,
constrictions (e.g. silencers) or are caused by the generation of strong vortex structures.
 A frequency analysis of the simulated gas flow or measured pressures should be conducted
to assess the likelihood of flow induced vibration.
*When designing transition pieces between duct sections of different cross-sectional areas
care should be taken to:
Maintain uniform gas flow velocity across the cross-sectional area.
Prevent flow detachment from the duct walls.
Provid the most economical pressure recovery (i.e. minimise pressure losses).
If necessary, guide vanes can be used to maintain flow uniformity, however they
introduce added complexity to the structural design (prone to fatigue failure) and
manufacture.

12.2.2 Structural Design of the Exhaust Duct

Some good practice guidelines for structural design of the exhaust duct are given below:
 The casing walls should be constructed of steel plate, 6 mm minimum thickness.
 The casing should have a design pressure based on the most severe combination of the wind
pressure/suction and 1.5 times the maximum operating pressure in the casing, but not less
than 50 mbar.
 Casing sections should not be designed horizontal (flat), but should be sloping to allow
drainage.
 It should be possible to drain all ducting.
 European Turbine Network A.I.S.B.L.

ETN
 Duct plate should be designed to limit the deflections to 1/100 of the span of plate between
stiffeners, taking full advantage of multispan continuity where appropriate, under design
conditions. The predicted deflection and natural frequencies can be calculate using structural
analysis methods, such as Finite Element Analysis (FEA).

12.1.2 Stiffeners
The exhaust duct stiffeners provide structural support for the large flat panels that make up flat sided
exhaust duct designs. Dividing up large panels with stiffeners will increase the natural frequency of
the panel sections and can be beneficial in reducing the succeptibility of the exhaust duct sections to
dynamic excitation (e.g. flow induced vibration from the exhaust flow).
Some good practice guidelines for stiffener design are given below:
 Duct stiffeners should not obstruct the flue gas path inside the exhaust duct.
 Duct stiffeners should terminate at the edges of a duct panel. Terminating duct stiffeners on
a panel, away from the edges can create stress concentrations in the panel and lead to
fatigue failure.
 Duct stiffeners whould be designed to limit deflection to 1/240 of the stiffener or support
span under design conditions. The predicted deflection and natural frequencies can be
calculate using structural analysis methods, such as Finite Element Analysis (FEA).
 All stiffeners shall be provided with weep holes so that rainwater cannot accumulate.

12.1.3 HSRG Casing Design

Some good practice guidelines for HSRG casing design are given below:
 All casing joints should be welded.
 HRSG casing joints (factory and field joints) should be gas tight to provide zero leakage.
 Field joints should be insulated and lagged in the field during assembly by means of
prefabricated internal liner sheets by the HRSG Supplier.
 Flanged connections should not be applied (to HSRG casings), unless seal welded after
installation.

12.1.4 Auxiliary Burner Casing Design

Some good practice guidelines for auxiliary burner casing design are given below:
 The flue gas velocity shall comply with the burner Supplier's requirements for optimum
performance over the entire operating envelope.

13. Auxiliary equipment

13.1 Dampers and damper controls

By-pass control can be by diverter or louver. The construction shall include the following details:
 Blade(s) and shaft(s) fabricated from stainless steel.
 Heat/corrosion resistant alloy seal elements.
 Self aligning bearings with bearings and bearing housings either in corrosion resistant
materials or properly protected by stainless steel oil filled or pressurised coverings.
 Maximum gas leakage of 1 % of total gas flow at 20 mbar pressure differential over the
whole
expected lifetime.
 European Turbine Network A.I.S.B.L.

ETN
 Fail safe position shall be bypass duct open and heating duct closed.
 If two flow control devices (one towards the bypass path, one towards the heat exchanger)
are used, a robust and reliable mechanical interlock system between those shall be used.
 Design and dimensioning of components shall take into account fluid dynamic forces from
the exhaust gas flow including turbulences in all expected operational modes.
 If throttling service is expected, the control characteristics and control areas of
stability/instability shall be carefully evaluated and documented during the design process.
 For throttling service, louvers are the preferred solution.
 Manual local operation and mechanical locking in the “open towards bypass” position shall
be possible. The actuator for the control damper shall be a hydraulic unit with local or
central hydraulic system.

The hydraulic cylinder shall be equipped with a lip seal. The actuator shall include all necessary limit
switches, positioners etc. inside a weather proofed casing.
The hydraulic system shall be equipped with radiation shield.
The actuator shall be designed for modulating regulation and will normally take its operating signals
from an outside controller with a temperature sensor in the outlet heating medium pipe for each
unit.
The actuator shall have override for manual operation.
The actuator shall have a manual locking device ensuring personnel safety during
maintenance/inspection.

13.2 Expansion Joints

Expansion bellows should preferably be of a circular design. All bellows shall be easily replaceable.
Expansion bellows shall be used between casing and ductwork to avoid transfer of relative
movement due to thermal stresses from the casing to the ductwork. The bellow fitted to the exhaust
collector exit flange shall be outside turbine enclosure.
Expansion bellows shall be made of heat resisting fabric reinforced material. The bellows shall be
adequately sealed and internally insulated with ceramic insulation material fibre packing.
The insulation shall be made by insulation jackets. A double sleeve or baffle with overlap made of at
least 4 mm stainless steel plate shall protect the fibre packing against the flow of the exhaust gas.
For the bellow at the interface of the ducting to the gas turbine package the allowable movement
that can be handled by the bellow both lateral and longitudinal during operation shall be
documented and taken into account during the design process. This evaluation shall include possible
movement or deflection of connected equipment and structures due to e.g. environmental
conditions or thermal expansion.
In addition permanent allowable misalignment of the bellow in comparison to achievable installation
tolerances of the GT-package towards the WHRU/HRSG-package shall be documented. Static
deflection of supporting structure shall be taken into account.
Expansion bellows shall be designed for minimum 10 years with 25 start/stop pr year of operation
before replacement is required. For this consideration, results from the CFD analysis (dynamic flow
 European Turbine Network A.I.S.B.L.

ETN
conditions in the bellow area) in comparison with allowable loads for the specific bellow design shall
be taken into consideration.

13.3 Silencers

A silencer in the ductwork should be avoided if possible. The silencing effect of the liquid filled coil
shall be considered when sizing the silencer. Noise levels at the outlet from turbine package and
noise requirements for outlets of WHRU/HRSG shall be used for the evaluation of the necessity and
rating of a silencer.
If a silencer is considered necessary, installation downstream the heat exchanger shall be evaluated.
Silencer elements (baffles) shall allow for easy inspection and replacement without