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• Better understand your HRSG design January 2023, Tampa, FL
• Learn HRSG fleet trends Course Topics:
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Problems • Flow Distribution Devices
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www.HRSGacademy.com
Copyright 2024 by HRST, Inc. 1
HRST Company Profile
Locations
–Headquarters: Minnesota, USA
–USA Regional Offices:
• California, Colorado, Florida, Robert Krowech
Maine, Maryland, Texas Founder

–International:
– Mexico Office
– Australia registration
– Colombia

Victor Ferris
CEO/President

Copyright 2024 by HRST, Inc. 2

 Decreasing
Startup Time in
Cycling HRSGs

Presented by: Daniel Acosta, P.E.

&
Cesar Moreno

Copyright 2024 by HRST, Inc. INSPECT. ANALYZE. SOLVE.® 3

 Why Decrease
Startup Time?
• Renewables like solar and
wind energy are becoming
more common across North
America
• Grid augmentation using
HRSG to support renewables
driving the need to start up
faster and more frequently
• Some combined cycle plants
starting to experience two or
more starts per day

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 4

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 5

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 6

Start-Up Procedure Review
• What are the “bottlenecks” in the start-up process?
o Gas turbine purge sequence
o Ability to pull vacuum
o Steam turbine hold periods
o HP Drum ramp rate/Drum swell

• Which of these bottlenecks are causing the greatest delays in

startup?
• How can these bottlenecks be eliminated?

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 7

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 8

 Venting Capacity
The steam turbine is typically the slowest piece of equipment to bring online
• Extremely tight tolerances between the
rotor and casing means that uniform
thermal growth must take place.
• Catastrophic damage could occur if OEM
recommended startup curves are not
followed.
• Finding alternative outlets for the steam
generated in the HRSG can allow the gas
turbine to continue to increase load while
the steam turbine continues its designed
warmup.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 9

 Venting Capacity
• The easiest/most economical place
to dump steam would be the
condenser.
• Most condensers are not sized to
“swallow” 100% steam load.
• Is there conditioning equipment on
bypass -> condenser line (i.e Att?)
• Additional locations are needed
for steam generated before steam
turbine admission is possible.
• Does the plant have sky valves?
• What is the flow limit for valves?

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 10

 Venting Case Study
• A plant wanted to enter the 10-minute non-spinning reserve market.
• They needed to put as many MWs on the grid as possible in 10
minutes.
• The plant has atmospheric venting capability to exhaust all 3 HRSGs
but did not have the demineralized water makeup capacity.

• The bypass to condenser line was re-

commissioned (abandoned for 20 years),
and the steam flow was split between
bypassing to condenser and bypassing
to atmosphere.
• Approach solved water makeup capacity
limitations.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 11

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Sealing steam source

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 12

 Demineralized Water Makeup Capacity
• Will venting steam outpace your ability
to make-up demineralized water?
• HRST can perform capacity checks of
demineralized water systems to verify
limitations.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 13

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 14

HP Drum Stress
Temperature/Pressure ramp rate causes
stress within HP drums.

Downcomer Nozzle Stress

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 15
HP Drum Stress
• HP drum at risk of fatigue damage when
pressure changes quickly.
• Pressure change causes a temperature
gradient through the vessel wall.
• Inside of the drum tracks the
saturation temperature,
• Outside of the drum lags as heat
slowly “bleeds” through the shell.
• If the temperature differential gets too
large, resulting stresses can start cracks
at discontinuities like large nozzles.
• So…..what does this mean for warm &
hot starts?

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 16

HP Drum Stress
Properties of Saturated Steam
700
600
500
Temperature [°F]

400
Saturation temperature increases
300 most rapidly at low
pressure. Therefore, a cold start has
200
much more potential to cause drum
100 shell damage than a hot start.

0
0 200 400 600 800 1000 1200 1400 1600
Pressure [psig]
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 17
HP Drum Stress HRSG OEM Guidelines:
• Cold Start = HP Drum pressure ≤ 30 psig
Hot Starts: • Warm Start = HP Drum pressure > 30 psig and < 800 psig
• Hot Start = HP Drum pressure ≥ 800 psig
• HP drum is already under
pressure and the shell is >500 Properties of Saturated Steam
deg F (per an OEM 700
definition). 600
∆T = < 100 F
• That’s GOOD!

Temperature [°F]
500
• Fast start no problem! 400
Cold & Warm Starts; 300
• Consider OEM guidelines on Hot Start
200
HP drum ramp rate Warm Start
100
• Warm Start ramp rate can
likely be accelerated above 0
OEM guidelines 0 200 400 600 800 1000 1200 1400 1600
Pressure [psig]
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 18
HP Drum Stress
HP Drum Ramp Rate Control – Corrective Actions
• Drum Stress Monitoring System
• Analyze limits of ramp rate on plant specific drum design and
arrangement
• A remaining life assessment can be performed to determine safe ramp
rates and amount of fatigue life left in the welds
• Measure shell and nozzle temperature rates of change directly with
thermocouples and use alarms
• Steam Sparging
• Maintains pressure in the drum when offline
• A cold start would then become a “warm start” with drum pressure
maintained lowering stress
• An auxiliary boiler or other external source of steam required

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 19

Fatigue Cracking - Ramp Rates
• Headers are typically more than 2” (50 mm) thick
• Tubes are typically 0.105-0.240”(3-5mm) thick
• Rapid exhaust temp increase heats tubes quickly, but the thick header
lags
• Stress results from tube diameter trying to change relative to the hole
in the header
• Analysis indicates stress tube diameter trying to change relative to hole in
header can be high enough for low cycle fatigue failures
• Experience shows few failures from this mechanism

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 20

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 21

 Attemperator Control
• Attemperator over
spray and hunting
are common
during startup.
• Analyzing PI data
will help
identifying this
issue

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 22

Attemperator Issue - Hunting
• Attemperator flow oscillates – chronic cycling
• Possibility of high-cycle fatigue in probe, liner, or piping
• Increases likelihood of water in superheater or reheater
• Broken attemperator nozzles
• Check long weld neck flange near probe
• Fix by tuning attemperator logic

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 23

Attemperator Issues - Hunting

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 24

Attemperator Problems
Pipe wall Failure at Nozzle

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 25

Attemperator Issue - Overspray
• At lower loads the GT ramp can have exhaust conditions that result in high
desuperheater spray flow to control steam temperature.
• If the inlet steam contains liquid water, it does not evenly distribute among
the tubes.
• Quenching does not mean quenching in the metallurgical sense. It means
cooling down some components more than others, generating thermal
stress that may only last for seconds.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 26

Attemperator Issue - Overspray
Steam From Attemperator

SH tubes have uniform, high

temp

Steam Out
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 27
Attemperator Issue - Overspray
Wet Steam From Attemperator

Tubes below inlet nozzles are

quenched and have a high
tensile load
Thermocouple reads at/near
saturation temp

Steam Out
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 28
Attemperator Issue - Overspray

Quenched & stretched tubes

buckle as they equalize
temperatures with neighboring
tubes

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 29

Attemperator Issue - Overspray
Tube Panel Looking Along Bottom Header

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 30

Consequences: Overspray
Downstream Pipe Cracking

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 31

 Attemperator Control
• Design details and control logic key to preventing
damage:
• Alarm if downstream temperature gets too close to the saturation temp
(50°F/28°C ΔT is safe for most designs)
• Alarm if attemperator is “hunting”. E.G. if the valve opens & closes twice or
more in a period of say five minutes
• Leak-by checks (DS Temp Change)
• Alarm if data indicates attemperator is leaking during operation, i.e. if there is
a ΔT across the attemperator when spraywater control demand is zero

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 32

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 33

 Gas Turbine Purge Time Optimization
• Purge requirements established by
NFPA Section 85 code.
• 8.8.4.2 - Purge prior to the light-off of
the combustion turbine shall be
accomplished by at least five-volume
changes at purge rate and for a
duration of not less than 5 minutes.
• 8.8.4.2.1.1 - This volume shall be
calculated based on the following:
• The volume from the combustion turbine
inlet to the portion of the HRSG or other
combustion turbine exhaust systems
where the combustion turbine exhaust
temperature is reduced to at least 56°C
(100°F) below the lowest autoignition
temperature of the fuel(s) for which the
system has been designed.
• The temperature profile in the HRSG in
8.8.4.2.1.1 (1) is based on the
combustion turbine operating at full load
with no supplementary HRSG firing.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 34

 Gas Turbine Purge Time Optimization
• Purge requirements established by NFPA Section 85 code.
• 8.8.4.2.1.2 - In no case shall the volume in 8.8.4.2.1.1 (2) be less than the
volume of the HRSG enclosure between the combustion turbine outlet
and the outlet of the first evaporator section in the HRSG. For other
combustion turbine exhaust systems without heat recovery, the purge
volume shall extend to the stack.

• 8.8.4.2.2.2 - The adequacy of the

purge rate shall be demonstrated
by one of the following methods:
• During the purge of the combustion
turbine, a flow rate of not less than 8
percent of full-load mass airflow is
provided through the HRSG or other
combustion turbine exhaust
systems, regardless of damper
leakage or degradation in the HRSG
enclosure or exhaust system.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 35

 Gas Turbine Purge Time Optimization
• Many CT OEMs use conservative
standard time
• Typical timeframes of 15 minutes
• Opportunities to reduce time through
analysis
• Recent HRST projects range from 5-8
minutes
• Counter doesn’t start until at purge
speed
• CT “spin down” to light off speed
afterward
• NFPA States minimum time of 5 minutes.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 36

 Purge Credit Feasibility
• Purge credit information by NFPA Section 85 code.
• 8.8.4.6.4 – The philosophy for combustion turbine purge credit is that a combustion turbine normal shutdown does not result in a hazardous atmosphere being introduced. Therefore,
a combustion turbine purge should not be required for subsequent startup provided that a combustion turbine purge credit is maintained.

• Two methods for obtaining a purge credit:

Pressurized Pipe Method:

In this method, the upstream vent valve shall
remain fully open, and the downstream vent
valve will remain in the closed position as
long as the purge credit is established. Air or
inert gas is introduced to maintain a
pressurized pipe section between the middle
and most downstream valves

Valve Proving Method:

After a combustion turbine normal shutdown,
the vent valves in Triple Block and Double Vent Valve Arrangement for Valve Proving Method
this arrangement shall be left open to
establish a purge credit. Continuous
monitoring of
the valve position and the pressure on the gas
piping is required for this approach

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 37

 Purge Credit Feasibility
• Determine requirements relative to
obtaining purge credit
• Likely involves reviewing:
• CT and Duct Burner Fuel P&IDs
• Ammonia supply system to AIG
• Purge credit retrofit
valving/hardware
• Control logic for purge timing
Pressurized Piping Section Method for Gaseous Fuels

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 38

Condensate Formation
Spraywater HP Drum at 500-700 psig
IN Pressure

Interstage
DSH Steam
HP Steam
Condenses
Out
In Superheaters

HP Evap

“Cold” Exhaust
At Purge (8 - 15 min)

SHTRS SHTRS
1&2 3&4
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 39
Condensate Formation

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 40

Consequences – Wet Header
RH header

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 41

 Fast Startup Considerations
• Startup procedure checks
• Venting capacity
• Demineralized water capacity
• Drum ramp rates
• Attemperator control
• Purge time calculation/credit
• Raising Condenser Vacuum

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 42

 Raising Condenser Vacuum – Sealing Steam
• Steam turbines need sealing steam in
service prior to pulling vacuum and
the admission of steam.
• If supplied from IP system, it may
take too long to develop necessary
pressure.
• This will place the GT on a holding
pattern.
• HRST has found alternative sealing
steam sources for customers.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 43

 Raising Condenser Vacuum – Sealing Steam
• Utilizing alternative sources:
• HP Steam
• Aux Boiler
• Online HRSG

• Non-Condensable Extraction
• Using vacuum pumps vs ejector.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 44

 Condenser Vacuum

• Steam Jet Air Ejectors

• Assists with vacuum
• Removes non-condensable
gases from condenser.
• Gases that will not
condense into a liquid (Air)
• Uses steam as motive force,
recoups motive steam via a
small condenser.
• More efficient than hogger.

45
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 45
 Condenser Vacuum

• Hogging Ejectors / Vacuum Pumps

• Hoggers – used on startup to raise

initial vacuum.
• Hogging Ejector - same principal as
SJAE, but does not recoup motive
steam
• Hogger Pump – vacuum pump

46
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 46
 Steam Turbine Gland Seals

• Labyrinth seal on ends of turbine

shaft.
• Tortuous path created for steam.
• Steam is applied to seals
• At LP shaft, prevents air in leakage
• At HP shaft, prevents steam
leakage

47
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 47
 Raising Condenser Vacuum Case Study
• HRST client wished to enter the 30-minute non-spinning reserve
market.
• They had the ability to dump 100% of steam load to condenser.
• The steam turbine gland seals were supplied by IP steam.
• The GT would ramp up, and then sit until enough pressure was
developed in IP system to place seals in service.
• Once seals were in service, they could continue to raise load and dump
steam to condenser.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 48

 Raising Condenser Vacuum Case Study
• Design work was
completed to use an
existing HP steam
letdown line to supply
seals until IP pressure was
sufficient.
• No longer was there a
hold point for the GT for
placing gland seals in
service.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 49

Steam Turbine Warm-Up Reduction

50
Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 50
Steam Turbine Warm-Up Reduction
• ST is large, if not largest
factor in startup time
• Correlates to rotor and shell
temperature soak
• Rotor/shell differential Image Source: POWER magazine

temperature
• How can you reduce the
warm-up timeframe?
• At least one plant has done
this with warming blankets

Image Source: POWER magazine

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 51

 Conclusion
• With grid leaning towards renewable sources, natural gas can take a
back seat.
• Many plants that were once base loaded are now cycling.
• Generating as much power as possible when called by their ISO is
more important than ever.
• Plants that are dormant much of the time are looking to enter the
non-spinning reserve markets, and every MW they can produce
counts.
• Decreasing start up time is a great way for aging plants to adapt to
the changing market.

Decreasing Startup Time in Cycling HRSGs – Copyright 2024 by HRST, Inc. 52

 Questions?

[email protected] | www.hrstinc.com
5909 Baker Road, Suite 500
Minnetonka, MN 55345 USA
INSPECT. ANALYZE. SOLVE.® 1-952-767-8100