Drum Boiler

SimSci ®
®
DYNSIM 5.3.2
DrumBoiler
December 2016
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Contents
Table of Contents
Introduction 5
Overview .......................................................................................................... 5
Summary of Classes ....................................................................................... 5
Class Hierarchy ............................................................................................... 5
BoilerDC 6
Introduction .................................................................................................... 6
Fundamentals ................................................................................................ 6
Single-Phase vs. Two-Phase .................................................................... 6
Boiler Circulation Pumps ........................................................................... 8
Boiler Circulation Pump Surge .................................................................. 9
Boiler Circulation Pump Burp .................................................................. 10
Configuring Recircs ................................................................................. 11
Configuring Drains .................................................................................. 12
Boiler Object Connections ...................................................................... 14
Boundary Specifications ......................................................................... 14
Available Malfunctions ............................................................................ 14
Examples ...................................................................................................... 14
Example 1 ............................................................................................... 14
Example 2 ............................................................................................... 17
Data Entry Window Usage .......................................................................... 25
Parameter Table - BoilerDC ........................................................................ 26
BoilerSepar34
Introduction .................................................................................................. 34
Fundamentals .............................................................................................. 34
State Pressure Calculation ..................................................................... 34
Enthalpy Calculation ............................................................................... 35
Mass, Void Fraction, and Volume Calculations ...................................... 36
Drum Level Calculations ......................................................................... 38
Metal Temperature Calculation ............................................................... 39
Specifying Geometry ............................................................................... 40
Specifying Design Operation Conditions ................................................ 42
Configuring Startup Blowdowns .............................................................. 42
Configuring Continuous Blowdowns ....................................................... 44
Configuring Vents.................................................................................... 45
Configuring Relief Valves ........................................................................ 46
Configuring Boiler Object Connections ................................................... 47
Configuring Flows that Exit from the Downcomer ................................... 47
Examples ...................................................................................................... 49
Example 1 ............................................................................................... 49
Example 2 ............................................................................................... 54
Data Entry Window Usage .......................................................................... 59
Parameter Table - BoilerSepar ................................................................... 60
FAQ ............................................................................................................... 84
BoilerSurf 85
Introduction .................................................................................................. 85
Fundamentals .............................................................................................. 85
Single-Phase vs. Two-Phase .................................................................. 85
Contents
Specifying Geometry ............................................................................... 93

Uncovered Tubes & Reverse Flow ......................................................... 95
Orifice Pressure Drop.............................................................................. 96
Specifying Tuning Factors ...................................................................... 96
Boiler Object Connections ...................................................................... 98
Examples ...................................................................................................... 99
Example 1 ............................................................................................... 99
Example 2 ............................................................................................. 103
Parameter Table - BoilerSurf .................................................................... 105
FAQ ............................................................................................................. 114
Introduction
Introduction
Overview
The DrumBoiler library provides models for simulating a drum/separator, downcomer and
waterwall system. The model objects include: BoilerDC, BoilerSepar, BoilerSurf.
These three models form a system and must be used together. There must always be at least one
BoilerSepar in the system. It must have at least one BoilerDC and BoilerSurf connected to it.
Alternatively, the boiler drum may be modeled using model objects from the NetSolve and
OnceThroughBoiler libraries. The DrumBoiler library objects provide superior shrink and swell
response during heating and pressurization.
Summary of Classes
Class Typical Uses See Also
Library/Class
BoilerDC Downcomer in drum/downcomer/waterwall loop NetSolve/Flow
NetSolve/Pump
NetSolve/Valve
BoilerSepar Drum in drum/downcomer/waterwall loop NetSolve/Flashtank
BoilerSurf Waterwall in drum/downcomer/waterwall loop OnceThroughBoiler/HxO

TB
Class Hierarchy
ModelObject
|_____________ BoilerDC
|_____________ BoilerSepar
|_____________ BoilerSurf
BoilerDC
BoilerDC
Introduction
BoilerDC extends ModelObject
The BoilerDC class models a downcomer (or group of downcomers) in a drum boiler system. The
downcomer brings water from the boiler drum to the base of the furnace waterwalls. This class
simulates the following:
• The fluid volume and metal mass of the downcomer piping (including filling/draining and
heat transfer)
• Any number of boiler circulation pumps
• Any number of economizer recirc valves
• Any number of drain valves
The solution of the BoilerDC algorithm is coordinated with the BoilerSepar and BoilerSurf
classes, and must be properly configured into a DrumBoiler system for a complete solution.
Fundamentals
Single-Phase vs. Two-Phase
The BoilerDC class models the volume of piping that conveys liquid from the BoilerSepar (at its
top) to the any number of BoilerSurf objects (at its bottom). Boiling/evaporation may occur in this
volume. The BoilerDC calculates the formation of steam bubbles in the downcomer and the steam
bubble void fraction in the downcomer. In the diagram below, the single-phase region is denoted
by “1p” and the two-phase region is denoted by “2p”.
DrumBoiler Version 5.3.2, December 2016 6

BoilerDC
The heat release from evaporation is given by
Qdcev = (Hdc – Hlsat2) * Rdc2p * Ldc * (1 – Adc) * Kdca / Kdcevt

where:
Hdc – Downcomer enthalpy (BTU/lb)
Hlsat2 – Saturated liquid enthalpy at downcomer two phase boundary (BTU/lb)
Rdc2p – Density at downcomer two phase boundary (lb/ft3)
Ldc – Downcomer two phase length (ft)
Adc – Downcomer two phase void fraction
Kdca – Downcomer cross-sectional area (ft2)
Kdcevt – Downcomer two phase length time constant (sec)

BoilerDC
The steam formation rate is given by
Wdcev = Qdcev * (Hvsati – Hlsati)

where:
Hvsati – Saturated vapor enthalpy at downcomer inlet (BTU/lb)
Hlsati – Saturated liquid enthalpy at downcomer inlet (BTU/lb)
The rate that steam moves from the downcomer to the BoilerSepar is given by
Fdcvx = Kdca * Rvsati * Vbub * Adc / (1 – Adc) * Kdcvbub

where:
Rvsati – Saturated vapor density at downcomer inlet (lb/ft3)
Vbub – BoilerSepar pool bubble velocity (ft/sec)
Kdcvbub – Downcomer bubble rise velocity scalar
The rate of change of steam in the downcomer is given by
dMdcps = Wdcev - Fdcvx
The change in downcomer void fraction is given by
dAdc = dMdcps / Kdca / Rvsati / Ldc
The pressure at the bottom of the downcomer is then calculated from the head of the single phase
and two phase lengths of the downcomer.
Boiler Circulation Pumps

The BoilerDC class contains built-in optional, boiler circulation pumps. These built-in pumps do
not require a pump object.
Any number of pumps may be configured. Set the size of the NBCP paramvector to the desired
number of pumps to be configured. All pumps are at the same elevation and each pump has its
own isolation valve.

BoilerDC
The downcomer does not calculate the circulation flow rate. The BoilerSurf objects each calculate
their own circulation flow rate and the downcomer sums them all.
The pressure increase across each pump is given by
Dpbcwp = k0 + k1 * w + k2 * w2
k0 = K0bcp1 * R / 144
k1 = K0bcp2 * 3.117
k2 = K0bcp3 * 1400 / R
where
K0bcp1 – zeroth order pump curve coefficient
K0bcp2 – first order pump curve coefficient
K0bcp3 – second order pump curve coefficient
R – liquid density in downcomer (lb/ft3)
w – flow rate thru pump (lb/sec)
Boiler Circ Pumps configuration
• Specify the number of boiler circ pumps using NBCP.
• Specify the speed of each boiler circ pump using the NBCP[i].
• Specify the pump curve coefficients using K0bcp1, K0bcp2, K0bcp3.
• Specify the boiler circ pump elevation using KBCPEL.
• Specify the boiler circ pump isolation valve area using ABCPSV[i].
• Set the minimum circulation rate parameter Kwwrmn2 in each BoilerSurf object based on the
number of boiler circ pumps in service. See the BoilerSurf class documentation.
Boiler Circulation Pump Surge

When a boiler circ pump is started, the drum level rapidly drops. When a pump is started, the
flow “surges” into tube volumes above the drum. When all the pumps are stopped, the liquid
drains back into the drum. The boiler circ pumps can be configured to reproduce this “surge”
effect.
Boiler C

BoilerDC
irc Pumps Surge configuration
• Specify the surge flow (when the pump is started) using KSurge.
• Specify the maximum surge flow of each pump using KSurgeMx[i].
• Specify the boiler circ pump un-surge rate coefficient with all pumps off. This controls how
much of the “surge” flow returns to the drum.
These values must be configured during testing.
Boiler Circulation Pump Burp

Prior to placing a boiler circ pump in service, it is common to “burp” all of the pumps. An
operator will perform the following procedure for each pump sequentially: start the pump, run it
for 5 seconds, and then stop the pump. This displaces air trapped in the boiler. The effect is that
when the first pump is started, the level drops. When the first pump is stopped, the level recovers
but not back to its original value. Each pump burp follows the same pattern but each successive
burp produces a smaller drop in level, as shown below.
The BoilerDC does not inherently produce this effect. It can be configured to produce this effect
with some additional logic blocks and the use of KSurgeMx. See the Example 2.

BoilerDC
Configuring Recircs
The BoilerDC class contains built-in economizer recirculation valves. These built-in recircs
neither require nor use a flow object. The pressure driving each recirculation flow reflects the
head of single phase liquid and two-phase mixture present in the downcomer as well as the head
from the boiler circ pumps in service.
Any number of these recircs may be configured. Set the NECRV parameter to the desired number
of recirc valves to be configured. There are two methods to configure the recirc flow coefficients.
Each recirc flow may be configured using a different method. The 2 configuration methods are
described below. Each recirc may be configured to exit the downcomer from a unique elevation
and discharge to a unique elevation. Set the KECDCEL and KECRCEL parameters respectively
for each recirc.
Note that KECDCEL and KECRCEL are measured from the drum/dc interface to the recirc line.
The recircs must be configured in the following order: OVECRV and then JECRV.
Recircs configured with a Valve object
• Any recirc may be directly connected to a valve object using the OVECRV[i] parameter
where I is the index in the drain array.
• The FECRV[i] (current mass flow) is calculated by the algorithm.

BoilerDC
• Mass flow through this recirc will be lost from the simulation model if not used elsewhere.
Recircs configured with a Flow Coefficient
• The flow coefficient may be calculated by the user and assigned to the JECRV[i] parameter,
where I is the index in the vent array.
• The FECRV[i] (current mass flow) is calculated by the algorithm.
• NECRV must be equal to or larger than the size of OVECRV. If NECRV is larger than the
size of OVECRV, the user must specify the remainder drains with JECRV.
• Mass flow through this drain will be lost from the simulation model if not used elsewhere.
Preserving Recirculation Mass Flow
• The recirc mass flow must be introduced into the economizer inlet header using a boundary
header and a Type = 5 flow.
Configuring Drains
The BoilerDC class contains built-in drains to ambient. These built-in drains neither require nor
use a flow object. The pressure driving each drain flow reflects the head of single-phase liquid
and two-phase mixture present in the downcomer as well as the head from the boiler circ pumps in
service. This flow is removed from the simulation unless the user configures objects to conserve
this flow.
Any number of these drains may be configured. Set the NDRAIN parameter to the desired
number of drains to be configured. There are two methods to configure the drain flow
coefficients. Each drain flow may be configured using a different method. The 2 configuration
methods are described below. Each drain may be configured to exit the downcomer from a unique
elevation and discharge to a unique pressure. Set the KDRAINEL and PDRAIN parameters
respectively for each drain.
Note that KDRAINEL is measured from the drum/dc interface to the drain.
The drains must be configured in the following order: OVDRAIN and then JDRAIN.

BoilerDC
Drains configured with a Valve object
• Any drain may be directly connected to a valve object using the OVDRAIN[i] parameter
• The FDRAIN[i] (current mass flow) is calculated by the algorithm.
• Mass flow through this drain will be lost from the simulation model.
Drains configured with a Flow Coefficient
• The flow coefficient may be calculated by the user and assigned to the JDRAIN[i] parameter,
• The FDRAIN[i] (current mass flow) is calculated by the algorithm.
• NDRAIN must be equal to or larger than the size of OVDRAIN. If NDRAIN is larger than
the size of OVDRAIN, the user must specify the remainder drains with JDRAIN.
Conserving Drain Mass Flow
• If it is desired to conserve the drain mass flow it must be introduced into a header or tank
using a boundary header and a Type = 5 flow.

BoilerDC
Boiler Object Connections

The BoilerDC downcomer object supplies fluid to any number of BoilerSurf waterwall surface
objects. The user must configure each downcomer with the surfaces it supplies. This is necessary
because a BoilerSepar drum may have multiple downcomers and each downcomer may supply
multiple surfaces. Use the OSURF array to specify the BoilerSurf objects that this BoilerDC
object supplies.
Guidelines for configuring BoilerDC object connections to other BoilerDrum library objects
• Use the OSURF array to specify the BoilerSurf objects that this BoilerDC object supplies.
• Each BoilerDC object must have at least one BoilerSurf object specified in OSURF.
Boundary Specifications
There are no boundary conditions that can be specified for this object.
Available Malfunctions
There are no malfunctions are available for this object.
Examples
Example 1
The following example is the downcomer from a natural circulation boiler.
This example has no boiler circ pumps. The downcomer has two drains and two economizer
recirc valves.
The example does not contain the parameter table for every model object:
• The waterwalls LEFT_WW, REAR_WW, FRONT_WW, and RIGHT_WW (BoilerSurf) and

drum DRUM (BoilerSepar) objects are not shown. See Example 1 of those classes.
• Only valve VECR_R is shown in detail as representative of both econ recirc valves in this
example.
• Only valve VDC_DRAIN1 is shown in detail as representative of both downcomer drain

valves in this example.

BoilerDC
BOILERDC: DWNCMR
Example downcomer
Parameter Assignment UOM Description
Drains
Head from downcomer drum

KELDRAIN 2 size interface to downcomer drain
valve

KELDRAIN[0] 184.5 ft interface to downcomer drain
valve

KELDRAIN[1] 184.5 ft interface to downcomer drain
valve
NDRAIN 2 Number of downcomer drains

BoilerDC
Downcomer drain valve object

OVDRAIN 2 size
connection

OVDRAIN[0] VDC_DRAIN1
connection

OVDRAIN[1] VDC_DRAIN2
connection
Economizer Recirculation
Economizer recirc valve flow

JECRV 1 size
coeff
Economizer recirc valve flow

coeff
JECRV[0] EQUATION size Equation: (VECR_L.J +
VECR_R.J)*LIM01((DRUM.P-
15)/3)
Elev dc-drum connex to dc-econ

KECDCEL 1 size
recirc line connex
Elevation of econ recirc line exit

KECDCEL[0] 198.75 ft
from DC
Elev dc-drum connex to econ-

KECRCEL 1
econ recirc line connex
Elevation of econ recirc line

KECRCEL[0] 219.5 ft
inlet to DC
Number of economizer recirc

NECRV 1
valves
Geometry Specifications
KDIAM 26 in Downcomer outer diameter
KLENGTH 185.5 ft Downcomer total length
KNUMBER 6 Number of parallel downcomers
KWALLTHK 1 in Downcomer wall thickness
Object-Object Configuration

BoilerDC
Reference to surfaces attached

OSURF 4 size
to this downcomer
OSURF[0] FRONT_WW Waterwall surface A
OSURF[1] REAR_WW Waterwall surface B
OSURF[2] RIGHT_WW Waterwall surface C
OSURF[3] LEFT_WW Waterwall surface D
MOVI: VECR_R
Example econ recirc valve (VECR_L similar)
FTRELAY 1 Full Travel Relay option
TIMECL 10.0 sec Time to close
TIMEOP 10.0 sec Time to open
(lb/sec)/sqrt(psi-
K 2.3507 Flow coefficient (VWO)
lb/ft3)
VALVES: VDC_DRAIN1
Example downcomer drain valve (VDC_DRAIN2 similar)
TIMEOP 15.0 sec Time to open
(lb/sec)/sqrt(psi-
lb/ft3)
Example 2
The following example is the downcomer from a forced circulation boiler.
This example has 4 boiler circ pumps. They are configured to “burp” and use logic blocks to
model the “burp”. The pump burp model reproduces drum level burp diagram in the
Fundamentals section. The pump burp model uses latches and timers to remove a certain amount
of water from drum (via a drain) so that the drum level permanently drops for each burp.
This example has one economizer recirc valve and two drains that are used to remove flow for
waterwall leak malfunctions.

BoilerDC
• Only motor MPBC_A is shown in detail as representative of all the pumps in this example.
• Only valve VBC_A is shown in detail as representative of all the pump isolation valves in this
example.
• Only latch SR_BWCP_A and timer TM_BURP_A are shown in detail as representative of all
the burp latches and timers in this example.
• Only malfunction MALF_WWLK_A is shown in detail as representative of all the

malfunctions in this example
• The waterwalls XWWA and XWWB (BoilerSurf) and drum DRUM (BoilerSepar) objects are
not shown. See Example 2 of those classes.
• The pump burp drain flow FBURP object is not shown. See Example 2 of BoilerSepar class.

BoilerDC
BOILERDC: DNCMR
Example downcomer
Circulating pump isolation

ABCPSV 4 size
valve stroke
ABCPSV[0] VBC_A.A Pump A isolation valve area
ABCPSV[1] VBC_B.A Pump B isolation valve area
ABCPSV[2] VBC_C.A Pump C isolation valve area
ABCPSV[3] VBC_D.A Pump D isolation valve area

BoilerDC
Boiler circ water pump

K0BCP1 263.79
coefficient

K0BCP2 0.0038
coefficient

K0BCP3 -4.0E-7
coefficient
Boiler circ pump elevation in

KBCPEL 58 ft
downcomer
(lb/sec)/sqrt(psi-
KSURGE 2000 BCWP surge rate coeff
lb/ft3)
BCWP surge limit

Equation: DNCMR.KSURGE *
KSURGEMX[0] EQUATION lb/sec CINTRP1(NUM_PMP_BURPD,
SURGETBL[0]) *
SR_BWCP_ALL.OUTR
BCWP surge limit

KSURGEMX[1] EQUATION lb/sec Equation:
DNCMR.KSURGEMX[0]
BCWP surge limit

DNCMR.KSURGEMX[0]
BCWP surge limit

DNCMR.KSURGEMX[0]
BCWP un-surge rate coeff with

KSURGOFF 1
all pumps off
Circulating pump normalized

NBCP 4 size
speed (each pump)
Pump A speed
NBCP[0] EQUATION Equation:
MPBC_A.SPEEDNORM
NBCP[1] EQUATION Pump B speed

BoilerDC
Equation:
MPBC_B.SPEEDNORM
Pump C speed
MPBC_C.SPEEDNORM
Pump D speed
MPBC_D.SPEEDNORM
Drains
Downcomer drain valve wide

JDRAIN 2 size
open flow coeff
Drain used for water wall leak

JDRAIN[0] EQUATION Equation: KWWTUBELK *
MALF_WWLK_A.OUT
Drain used for water wall leak

JDRAIN[1] EQUATION Equation: KWWTUBELK *
MALF_WWLK_B.OUT
NDRAIN 2 Number of downcomer drains
Elev dc-drum connex to dc-econ

KECDCEL 1 size
recirc line connex
Elevation of econ recirc line exit

KECDCEL[0] 270 ft
from DC
Elev dc-drum connex to econ-

KECRCEL 1
Elevation of econ recirc line

KECRCEL[0] 268 ft
inlet to DC
Number of economizer recirc

NECRV 1
valves
Economizer recirc valve object

OVECRV 1 size
connection

BoilerDC
OVECRV[0] VERC Econ recirc valve
Geometry Specifications
KDIAM 34 in Downcomer outer diameter
KLENGTH 202.9 ft Downcomer total length
KNUMBER 1 Number of parallel downcomers
KWALLTHK 2 in Downcomer wall thickness

OSURF 2 size
to this downcomer
OSURF[0] XWWA Waterwall surface A
OSURF[1] XWWB Waterwall surface B
MOTOR: MPBC_A
Example boiler circ pump motor (MPBC_B, MPBC_C, MPBC_D similar)
SPEEDREF 1750 rpm Full speed reference
MOVI: VBC_A
Example boiler circ pump isolation valve (VBC_B, VBC_C, VBC_D similar)
(lb/sec)/sqrt(psi-
lb/ft3)
VALVES: VERC
Example boiler circ pump recirc valve
(lb/sec)/sqrt(psi-
lb/ft3)

BoilerDC
STATIC_FLOAT: KWWTUBELK
Waterwall tube leak flow coefficient
Value 0.663
CUSTOMMALFANALOG: MALF_WWLK_A
Example waterwall leak malfunction (MALF_WWLK_B similar)
All default values
DYNAMIC_INT: NUM_PMP_BURPD
Number of pumps burped. A burped pump is a pump that has been started.
STATIC_FLOAT: SURGETBL
Normalized surge flow vs. number of “burped” pumps
STATIC_FLOAT: BURPDRNTBL
Normalized burp flow sent to drain vs. number of “burped” pumps
LATCH: SR_BWCP_A
Example boiler circ pump burp latch (SR_BWCP_B, SR_BWCP_C, SR_BWCP_D similar)

BoilerDC
Reset signal
RESET EQUATION Equation: (Drum.VBDP < 100)
and (either drum vent open)
SET PBC_A.POS Set signal
TIMER: TM_BURP_A
Example boiler circ pump burp timer (TM_BURP_B, TM_BURP_C, TM_BURP_D similar)
PRESET 5 sec Preset Time
Type of Timer
TYPE 1
(1 = Pulse)
START SR_BWCP_A.OUT Start signal
LATCH: SR_BWCP_ALL
This latch turns off the surge after all BCPs are burped
Reset signal
RESET EQUATION Equation: ( Drum.VBDP <

100) and (either drum vent
open)
SET TM_BURP_ALL.OUT Set signal
TIMER: TM_BURP_ALL
Example boiler circ pump burp timer
PRESET 5 sec Preset Time
Type of Timer
TYPE 3
(3 = On Delay)
Start signal
START EQUATION
Equation: (NUM_PMP_BURPD > 3.5)

BoilerDC
NSFLOW: FBURP
Example pump burp flow. This flow exits the DRUM object and goes to a drain boundary header. It is not
shown in the diagram above.
Type of flow calculation

TYPE 5
(5 = User defined flowrate)
User defined exit flow rate

Equation: LIM01(TM_BURP_A.OUT +
TM_BURP_B.OUT + TM_BURP_C.OUT +
FFX EQUATION lb/sec
TM_BURP_D.OUT) *
10000 * CINTRP1(NUM_PMP_BURPD,
BURPDRNTBL[0])
SUM: SUM_NUM_PMP_BURPD
Calculates the number of pumps burped. It is not shown in the diagram above.
IN 4 Input
IN[0] SR_BWCP_A.OUT
IN[1] SR_BWCP_B.OUT
IN[2] SR_BWCP_C.OUT
IN[3] SR_BWCP_D.OUT
OUT NUM_PMP_BURPD Output
Data Entry Window Usage

There is no data entry window for this object.

BoilerDC
Parameter Table - BoilerDC
Advanced Tuning Constants
Parameter Description UOM Eq Arr Sort Dft Dft

Name OK Size Out
Cls Val
Kdcevt Time constant for downcomer sec Yes N/A No KF 3.0

two phase length
Kdcvbub Scalar on downcomer bubble Yes N/A No KF 1.0

rise velocity
Kldct Time constant for downcomer sec Yes N/A No KF 15.0

two phase length

Description UOM Eq Arr Sort Dft Dft
Parameter
OK Size Out
Name
Cls Val
Abcpsv Circulating pump isolation Yes NBCP No DF 0.0

valve stroke 0-1
Valve area
Dpbcwp Circulating pump pressure rise psia No N/A No DF 0.0
Dpbcwpdw Circulating pump pressure rise No N/A No DF 0.0

sensitivity to flow (psi/
lbm/
sec)
Dvsurge Deriv. of BCWP start Surge ft3 No N/A No DF 0.0

volume
K0bcp1 Boiler circ water pump Yes N/A No KF 0.0

coefficient

coefficient

coefficient
Kbcpel Boiler circ pump elevation in ft Yes N/A No KF 0.0

BoilerDC
downcomer
Ksurge BCWP surge rate coeff Yes N/A No KF 10.
Ksurgemx BCWP surge limit Yes NBCP No KF 20.
Ksurgoff BCWP un-surge rate coeff Yes N/A No KF 0.5

with all pumps off
Nbcp Circulating pump normalized Yes None No DF

speed 0-1
Pbcwp Pressure at boiler circ pump psia No N/A No DF 0.0

discharge header
Vsurge BCWP start Surge volume ft3 No N/A No SF 0.0
Wbcp Flow through each boiler lb/sec No NBCP No DF 0.0

circulating pumps
Wbcpt Total flow through the boiler lb/sec No N/A No DF 0.0

circulating pumps
Wsurge BCWP start Surge flow lb/sec No N/A No DF 0.0
Downcomer Inlet Conditions (Dynamically Calculated)

Parameter
OK Size Out
Name
Cls Val
Pdci Pressure at downcomer - drum psia No N/A No DF 0.0

interface
Wdci Flow from boiler drum to the lb/sec No N/A No DF 0.0

downcomer
Drains
Parameter
OK Size Out
Name
Cls Val
Fdrain Downcomer drain valve flow lb/sec No NDRA No DF 0.0

IN
Jdrain Downcomer drain valve wide (lb/sec Yes NDRA No KF 0.0

open flow coeff )/sqrt(p IN
si-
lb/ft3)
Kdrainel Head from downcomer drum ft Yes NDRA No KF 0.1

interface to downcomer drain IN

BoilerDC
valve
Ndrain Number of downcomer drains No N/A No KI 0
OVdrain Downcomer drain valve object No None No VBA

connection SE
Pdrain Downcomer drain downstream psia Yes NDRA No DF PAMB

pressure IN
Parameter
Name OK Size Out
Cls Val
Dpecrv Pressure drop across psia No NEC No DF 0.0

economizer recirc valve
RV
Fecrv Economizer recirc valve flow lb/ No NEC No DF 0.0
sec RV
Jecrv Economizer recirc valve flow Yes NEC No KF 0.0

coeff
RV
Kecdcel Elev dc-drum connex to dc- ft Yes NEC No KF 0.0

RV
Kecrcel Elev dc-drum connex to econ- ft Yes NEC No KF 0.0

RV
Necrv Number of economizer recirc No N/A No KF 0.0

valves
OVecrv Economizer recirc valve Yes None No VBA

object connection SE
Recrv Elev avg econ density over lb/ Yes NEC No DF 0.0
distance Kecrcel
ft3 RV
Filling Parameters (Dynamically Calculated)

OK Size Out
Name
Cls Val
Dvdcfill Derivative of downcomer fluid ft3/ No N/A No DF 0.0

BoilerDC
volume filled
sec
Vdcfill Downcomer fluid volume ft3 No N/A No SF 0.0

filled
Wdcfill Downcomer filling flow lb/ No N/A No DF 0.0
sec
Xfull Downcomer volume fraction No N/A No DF 0.0

full
Fluid Conditions (Dynamically Calculated)

Parameter
OK Size Out
Name
Cls Val
Dm2p Downcomer mass r.o.c. lb/sec No N/A No DF 0.0

correct due to ww 2p mass
Dmdc Downcomer mass rate of lb/sec No N/A No DF 0.0

change due to enthalpy
derivative
Dmsc Downcomer mass r.o.c. lb/sec No N/A No DF 0.0

correct due to ww 1p mass
Dmww Downcomer mass r.o.c. lb/sec No N/A No DF 0.0

correct due to ww 2p
boundary movement
Dpdch Static head of downcomer psia/ No N/A No DF 0.0

water column rate of change
sec
Dpdcst Static head of downcomer psi No N/A No DF 0.0

water column
Fdcvx Rate of downcomer steam lb/sec No N/A No DF 0.0

flow to drum from DC boiling
Mdc Total fluid mass in lbm No N/A No DF 0.0

downcomer
Pdc2 Pressure at downcomer two psia No N/A No DF 0.0

phase boundary
Qdcev Heat released in evaporation Btu/ No N/A No DF 0.0
sec
Rdc1p downcomer density in single lb/ft3 No N/A No DF 0.0

phase region

BoilerDC

Parameter
OK Size Out
Name
Cls Val
Rdc1pdh downcomer density in single No N/A No DF 0.0

phase region sensitivity to
pressure (lb/ft3/psi)
Rdc2p Mass average downcomer lb/ft3 No N/A No DF 0.0

density in two phase region
Wdcev Vapor flow created in lb/sec No N/A No DF 0.0

downcomer evaporation
Wdclx Rate of downcomer liquid lb/sec No N/A No DF 0.0

displacement due to stm form
in DC
Fluid States (Dynamically Calculated)

Name OK Size Out
Cls Val
Adc Downcomer two phase void frac No N/A No SF 0.0

fraction
tion
dAdc Derivative of two phase void frac No N/A No DF 0.0

fraction
tion
/sec
dHdc Derivative of downcomer Btu/ No N/A No DF 0.0

enthalpy
lb/
sec
dLdc Derivative of downcomer two ft/s No N/A No DF 0.0

phase length
ec
Hdc Downcomer enthalpy Btu/ No N/A No SF 43.0
lb
Ldc Downcomer two phase length ft No N/A No SF 0.0

BoilerDC
Geometry (Calculated by the Pre-processor)

Parameter
Name OK Size Out
Cls Val
Kdca Downcomer cross section flow ft2 Yes N/A No KF -999

area - preprocessed
Kdch Elev from downcomer drum ft Yes N/A No KF -999

interface to downcomer
bottom - preprocessed
Kdcm Downcomer metal mass times Btu/F Yes N/A No KF -999

specific heat - preprocessed
Kdcv Downcomer fluid volume - ft3 Yes N/A No KF -999

preprocessed
Kdcvtube Downcomer fluid volume - ft3 No N/A No KF -999

preprocessed
Geometry Specification
Parameter
OK Size Out
Name
Cls Val
Kdiam Downcomer outer diameter in Yes N/A No KF 10.0
Klength Downcomer total length ft Yes N/A No KF 10.0
Knumber Number of parallel Yes N/A No KF 5.0

downcomers
Kwallthk Downcomer wall thickness in Yes N/A No KF 1.0
Parameter
Name OK Size Out
Cls Val
Osurf Reference to surfaces attached to No None No BOIL

this downcomer E
Each surface that this RSU

downcomer feeds must be listed RF
here, as well as connected to the
OSurf parameter of the same
BoilerSepar that this downcomer
is attached

BoilerDC
Saturation Properties (Dynamically Calculated)

Parameter
OK Size Out
Name
Cls Val
Hlsat2 Saturated liquid enthalpy at 2 Btu/ No N/A No DF 0.0

phase boundary
lb
Hlsati Saturated liquid enthalpy at Btu/ No N/A No DF 0.0

PdcI
lb
Hvsat2 Saturated vapor enthalpy at 2 Btu/ No N/A No DF 0.0

phase boundary
lb
Hvsati Saturated vapor enthalpy at Btu/ No N/A No DF 0.0

PdcI
lb
Pdcb Saturated pressure at psia No N/A No DF 0.0

downcomer enthalpy
Rlsat2 Saturated liquid density at 2 lb/ft3 No N/A No DF 0.0

phase boundary
Rlsati Saturated liquid density at lb/ft3 No N/A No DF 0.0

PdcI
Rvsat2 Saturated vapor density at 2 lb/ft3 No N/A No DF 0.0

phase boundary
Rvsati Saturated vapor density at lb/ft3 No N/A No DF 0.0

PdcI
Tsat2 Saturated temperature at 2 F No N/A No DF 0.0

phase boundary
Tsati Saturated temperature at PdcI F No N/A No DF 0.0
Water Wall Inlet Conditions (Dynamically Calculated)

Name OK Size Out
Cls Val
Phd Pressure at waterwall inlet psia No N/A No DF 0.0

header
Thd Temperature at waterwall inlet F No N/A No DF 0.0

header

BoilerDC
Wdcx Flow from the downcomer to lb/sec No N/A No DF 0.0

the boiler surfaces
Legend:
Dfl Cls Default parameter class:
KB - Static Boolean SB - State Boolean DB - Dynamic Boolean
KI - Static Integer SI - State Integer DI - Dynamic Integer
KF - Static Float SF - State Float DF - Dynamic Float
KD - Static Double SD - State Double DD - Dynamic Double
Dft Val A value here indicates the parameter’s default value. If the parameter is static, no value
indicates that the parameter is optional unless otherwise noted.
Eq Ok An equation can be attached to the parameter if the corresponding value is Yes.
Arr Siz A value here if indicates the size of the array. No value indicates that the parameter is not a
vector.
UOM Internal units of measure.
Please refer to the Netsolve Fundamentals section for pressure node base parameters, flow
device base parameters, and parameters associated with the flash or reaction submodel.

BoilerSepar
BoilerSepar
Introduction
BoilerSepar extends NSHeader
The BoilerSepar class models the drum separator in a drum boiler system. The drum separator
model includes evaporation / condensation directly from / to the liquid pool, condensation to both
the shell and internal metal, and bubbling of the pool, with pool level swell accounting for
bubbles. The drum separator, together with its downcomers and surfaces, acts as a closed system,
calculating its own pressure, including vapor and non-condensables partials. This class simulates
the following:
• The fluid volume and metal mass of the drum separator (including filling/draining and heat
transfer)
• Any number of blowdown valves
• Any number of relief valves
• Any number of vent valves
Pressure solution types (mass balance)
• Compressible State
Enthalpy solution types (energy balance)
• State
The solution of the BoilerSepar algorithm is coordinated with the BoilerDC and BoilerSurf
Fundamentals
The boiler drum model computes drum pressure, pool volume (level) and enthalpy, and steam and
metal temperatures under all operating conditions. It also computes pool void fraction under
transient conditions such as rapid depressurization.
State Pressure Calculation
The Boiler Drum model uses a compressible state pressure calculation. The change in drum
pressure is calculated from an energy balance on the steam given by:

BoilerSepar
dTbd
dPv
= dt =
(Wrxs + Fbdi + Fdcvx + Fbdfl − FsteamTot )* Hfg + Qsub − Qsm
dt dTsat
(Kbdc + Cps * RvSat *Vbds )* dTsat
dP dP
where: Pv = partial pressure of steam
Tbd = temperature of steam
Wrxs = saturated steam flow entering drum from boiler surfaces
Fbdi = steam flow entering drum
Fdcvx = steam flow entering drum from downcomer flashing
Fbdfl = steam flow entering drum from pool flashing
FsteamTot = sum of steam flows leaving drum (to superheaters, relief valves, etc.)
Hfg = enthalpy of vaporization
Qsub = heat transfer from liquid entering drum cooling to saturation liquid enthalpy
and heat transfer from downcomer and surface flashing
Qfld = heat transfer from pool flashing
Qsm = heat transfer, steam to metal (including sat conn if present) (internal variable)
Kbdc = thermal capacity of separator metal mass (internal variable)
Cps = steam specific heat capacity (internal variable)
RvSat = saturated vapor density at drum total pressure
Vbds = volume available to steam in drum and waterwalls
dTsat/dP = derivative of saturated steam temp with respect to pressure
A small amount of boiler drum metal is lumped with the steam to prevent numerical instabilities at
low pressures. The partial pressure of air is also calculated with assumed inward leakage when the
partial pressure of steam is below atmospheric. Total pressure is the sum of partial pressures of air
and steam.
Enthalpy Calculation

BoilerSepar
The drum separator model includes evaporation / condensation directly from / to the liquid pool,
condensation to both the shell and internal metal, bubbling of the pool, and pool level swell.
The change in drum pool enthalpy is given by:
dH Wbdi ( Hbdi − H ) + Wbdpi ( HlSat1 − H ) + Fbdcon( HlSat − H ) − Fbdfl ⋅ Hfg + Qsub − Qlm
=
dt Mbdpw
where: H = drum pool enthalpy
Wbdi = Feedwater flow to drum
Hbdi = Enthalpy of feedwater flow to drum
Wbdpi = Drum pool net flow rate – except liquid blowdowns
HlSat1 = Saturated liquid enthalpy at vapor pressure
Fbdcon = Drum condensation flow rate
HlSat = Saturated liquid enthalpy at total pressure
Qlm = heat transfer, pool to metal (internal variable)
Mbdpw = drum pool water mass
Mass, Void Fraction, and Volume Calculations
The rate of change of drum pool water mass is given by:
dMbdpw
= Wbdi + Wbdpi + Fbdcon − Fbdfl − Wdc
dt
where: Wdc = Flow from boiler drum to downcomer (water exit flow through downcomers,
blow down valves, economizer recirculation, etc.)
Condensation and evaporation are transient occurrences during rapid pressurization or

depressurization.

BoilerSepar
The change in drum pool void fraction is given by:
dAbdp Fbdfl − Wpvx

=
dt RvSat ⋅ Vbdp
where: Abdp = pool void fraction
Wpvx = rate of steam emitting the pool (internal variable)
RvSat = density of saturated vapor density
Vbdp = pool volume (water plus steam bubbles)
The change in pool volume is given by:
dVbdp 1 dMbdpw dAbdp

= + Vbdp
dt R dt dt
where: R = density of pool

BoilerSepar
Drum Level Calculations
Drum level is then found from pool volume and pool geometry.

BoilerSepar
Metal Temperature Calculation
Drum metal temperatures are calculated at various places consistent with predicting measured
temperatures and energy losses to the surroundings. The locations of various drum metal
temperatures, coefficients and heat flows are shown below.
The drum metal consists of a number of concentric shells equal to the value of the NODES
parameter. In the diagram above, NODES = 2 (and NODESP1 = 3). The thickness fraction of
each node is given by THICKFRAC and defaults to equal thickness for each node. The drum
metal shells have both an upper portion and lower portion. Heat transfer is calculated from the

BoilerSepar
fluid to the inner shell, between shells, and from the outer shell to ambient. Heat transfer is also
calculated between the upper protion and the lower portion of each shell. The drum metal also has
an internal portion that is assumed to be in equalibrium with the vapor temperature.
The Riser and Saturated Connecter masses are optional. If Kbdmrc and Kbdmsc (the thermal
capacitances) are greater than zero, then the Riser and Saturated Connecter will exist, respectively.
If the optional masses exist, then heat transfer is calculated from the outer shell to the mass, fluid
to the mass, and from the mass to ambient.
Specifying Geometry
The BoilerSepar class geometry is a horizontal cylinder. The user may specify the Kbdr, Len,
Thk, and Volumecor parameters. If the user does not specify them, defaults will be used. The
BoilerSepar class does not use the D parameter (like the other NetSolve headers and tanks).
Diameter and Wall Thickness
The drum diameter (in inches) and wall thickness (in feet) are calculated as follows:
If Thk is specified
D = (Kbdr * 12 + Thk) * 2
Wallthick = Thk / 12
Else
D = Kbdr * 12 * 2
Wallthick = 0.6
Wallthick is limited to 1.5 or 0.4*Kbdr, whichever is smaller
Drum Length
The drum length (in feet) is calculated as follows:
If Len is specified
Kdbl= Len
Else
Kbdl = 100.0

BoilerSepar
Available Fluid Volume
The internal volume available to steam, not occupied by internal metal, (in ft3) is calculated as
follows:
Kbdveq = Volumecor * internal volume
where internal volume = PI * Kbdr * Kbdr * Kbdl. Volumecor must be greater than 0.33 and may
be greater than unity.
Internal Metal Mass
The internal metal mass is proportional to the internal volume:
Kbdmic = 500lb/ft3 * 0.11BTU/lb/F * SepMasFac * internal volume
Sepmasfac must be greater than 0.02 and less than 2.0.
Drum shell metal mass is calculated as a cylindrical shell. The end caps are assumed flat plates.
Riser and Saturated Connector masses, if specified, will each be limited to no more than one half
of the total drum mass, so as not to dominate the drum.
Guidelines for configuring BoilerSepar object geometry
• Specify the boiler drum internal radius, KBDR.
• Specify the boiler drum length, LEN.
• Specify the boiler drum wall thickness, THK.
• Specify the number of nodes, NODES, (or shells).
• Specify the number of nodes + 1, NODESP1, to be (you guessed it) NODES + 1.
Optional guidelines for configuring BoilerSepar object geometry
• Specify the boiler drum steam fraction of total internal volume, VOLUMECOR, if the default
is not acceptable.
• Specify the separator mass factor, SEPMASFAC, if the default is not acceptable.
• Specify the drum cylinder wall thickness fraction per node, THICFRAC[i], for every node if
equal thickness is not desired.
• Specify boiler drum riser connector metal themal capacity (mass * Cp), KBDMRC, if a riser
connector is present.
• Specify boiler drum saturated connector metal themal capacity (mass * Cp), KBDMSC, if a
saturated connector is present.

BoilerSepar
Specifying Design Operation Conditions
The BoilerSepar class has two important design parameters, Fdesign and Pdesign.
Fdesign - this is the design drum steam exit flowrate. This parameter will internally default to
1000 lb/sec if not specified. It is used to:
• Calculate the minimum waterwall recirculation rate (assumed 60% of the Fdesign)
• Calculate heat transfer loss to ambient cofficients for metal nodes.
• Calculate safety valve sizing and relief pressure settings.
Pdesign - this is the design drum pressure. The BoilerSepar class cannot exceed 3200 psia
• Calculate safety valve sizing and relief pressure settings.
Guidelines for configuring BoilerSepar design conditions
• Specify design drum steam exit flowrate, FDESIGN.
• Specify design drum pressure, PDESIGN.
• Specify the fluid type, FLUID, to 1.
• Ensure that the operating conditions are always have a circulation ratio is greater or equal to
4. The total flow through the BoilerDC and through the BoilerSurf objects should be at least
4 times the exiting steam flow. If your operating conditions are below this, consider using the
FlashTank object instead.
Configuring Startup Blowdowns
The BoilerSepar class contains built-in startup blowdown drains. These built-in drains neither
require nor use a flow object. The pressure driving each drain flow reflects the head of single-
phase liquid in the drum. This flow is removed from the simulation unless the user configures
objects to conserve this flow.
Any number of these drains may be configured. Set the NBLOSTART parameter to the desired
number of drain valves to be configured. There are two methods to configure the drain flow
coefficients. Each drain flow may be configured using a different method. The two configuration
methods are described below. All drains exit from the drum / downcomer interface and may be
configured to discharge to a unique pressure. Set the PBLOSTART.

BoilerSepar
The recircs must be configured in the following order: OVBLOSTART and then JBLOSTART.
• Any drain may be directly connected to a valve object using the OVBLOSTART[i] parameter
• The FBLOSTART[i] (current mass flow) is calculated by the algorithm.
• The flow coefficient may be calculated by the user and assigned to the JBLOSTART[i]
parameter, where I is the index in the vent array.
• The FBLOSTART[i] (current mass flow) is calculated by the algorithm.
• NBLOSTART must be equal to or larger than the size of OVBLOSTART. If NBLOSTART

is larger than the size of OVBLOSTART, the user must specify the remainder drains with
JBLOSTART.

BoilerSepar
Configuring Continuous Blowdowns

The BoilerSepar class contains built-in continuous blowdown drains. These built-in drains neither
require nor use a flow object. The pressure driving each drain flow does not reflect the head of
single-phase liquid in the drum. This flow is removed from the simulation unless the user
configures objects to conserve this flow.
Any number of these drains may be configured. Set the NBLOCON parameter to the desired
number of drain valves to be configured. There are two methods to configure the drain flow
coefficients. Each drain flow may be configured using a different method. The two configuration
methods are described below. All drains exit from the drum / downcomer interface and may be
configured to discharge to a unique pressure. Set the PBLOCON.
The recircs must be configured in the following order: OVBLOCON and then JBLOCON.
• Any drain may be directly connected to a valve object using the OVBLOCON[i] parameter
• The FBLOCON[i] (current mass flow) is calculated by the algorithm.

BoilerSepar
• The flow coefficient may be calculated by the user and assigned to the JBLOCON[i]
parameter, where I is the index in the vent array.
• The FBLOCON[i] (current mass flow) is calculated by the algorithm.
• NBLOCON must be equal to or larger than the size of OVBLOCON. If NBLOCON is larger
than the size of OVBLOCON, the user must specify the remainder drains with JBLOCON.
Configuring Vents
The BoilerSepar class contains built-in vents to ambient. These built-in vents neither require nor
use a flow object. Any number of these vents may be configured. Set the NVENT parameter to
the desired number of vents to be configured. There are two methods to configure the vent flow
coefficients. Each vent flow may be configured using a different method. The two configuration
methods are described below, with an example that contains one vent of each type. The vents are
internally configured to be at the top of the drum.
The vents must be configured in the following order: OVVENT and then JVENT.

BoilerSepar
Vents configured with a Valve object
• Any vent may be directly connected to a valve object using the OVVENT[i] parameter where
I is the index in the vent array.
• The FVENT[i] (current mass flow) is calculated by the algorithm.
• Mass flow through this vent will be lost from the simulation model.
Vents configured with a Flow Coefficient
• The flow coefficient may be calculated by the user and assigned to the JVENT[i] parameter,
• The FVENT[i] (current mass flow) is calculated by the algorithm.
• NVENT must be equal to or larger than the size of OVVENT. If NVENT is larger than the
size of OVVENT, the user must specify the remainder vents with JVENT.
• Mass flow through this vent will be lost from the simulation model.
Configuring Relief Valves

The BoilerSepar class contains built-in relief valves to ambient. These built-in vents do not
require a flow object. These relief valves can be configured to open and close automatically based
on drum pressure. These also relief valves have manual open and close overrides. The relief
valves are internally configured to be at the top of the drum.
Guidelines for configuring relief valves
• Any number of relief valves may be configured on a single drum. The number of relief
valves is determined by the number of KRELIEF[] array elements defined.
• The following must be set for each relief valve: KRELIEF (full open flow coefficient),
KRELPOP (popping pressure), and KRELRES (reset pressure).
• Setting the SRELGAG switch to 1 will force the relief valve closed, regardless of pressure or
power pop switch position. SRELGAG overrides SRELPOP.
• Setting the SRELPOP (power pop) switch to 1 will cause the relief valve to open regardless of
pressure, but not if SRELGAG is set.
• The ARELIEF (current normalized area) and FBDRV (current mass flow of all relief valves)
are calculated by the algorithm.
• Mass flow through relief valves is lost from the simulation.
The BoilerSepar class will auto size the relief valves based on Fdesign, Pdesign, and the number
of valves specified. If the user sets one of the following parameters to -1, then it will be auto
configured: KRELIEF, KRELPOP, KRELRES.
Optional guidelines for configuring relief valves
• Specify the number of relief valves and set the elements of KRELIEF to -1 for auto flow
coefficient sizing.

BoilerSepar
• Set the elements of KRELPOP to -1 for auto popping pressure sizing.
• Set the elements of KRELRES to -1 for auto reset pressure sizing.
Configuring Boiler Object Connections
The BoilerSepar drum object supplies fluid to any number of BoilerDC downcomer objects and
receives fluid from any number of BoilerSepar waterwall surface objects. The user must
configure each drum with the downcomers it supplies and the surfaces that supply it. Use the
ODC array to specify the BoilerDC objects that this BoilerSepar object supplies. Use the OSURF
array to specify the BoilerSurf objects that supply this BoilerSepar object.
Guidelines for configuring BoilerSepar object connections to other BoilerDrum library

objects
• Use the ODC array to specify the names of the BoilerDC objects that this BoilerSepar object
supplies.
• Each BoilerSepar object must have at least one BoilerDC object specified in ODC.
• Use the OSURF array to specify the BoilerSurf objects that supply this BoilerSepar object.
• Each BoilerSepar object must have at least one BoilerSurf object specified in OSURF.
Configuring Flows that Exit from the Downcomer

The BoilerSepar object is the interface for all flow objects entering and exiting the drum boiler
system. All flows entering and exiting the drum boiler system must be connected to the
BoilerSepar OFi and OFx arrays. However, it is possible to specify a flow object that exits from
the downcomer. A flow object exiting from the downcomer has the enthalpy and non-
condensables of the downcomer.
Guidelines for configuring flows that exit from the downcomer
• Any flows that exit the downcomer must be listed first in the OFX array. All flows that exit
the drum normally follow.
• For every flow that exits the downcomer in the OFX array, create an entry in the ODCFX
array. Set this entry to the name of the downcomer object from which the flow exits.
• For every flow that exits the downcomer in the OFX array, be sure to set it entry in the LX
array to the proper negative value (distance below the bottom of the drum).

BoilerSepar
The following boundary conditions can be independently specified for the BoilerSepar:
• TAMB - ambient temperature
• PAMB - ambient pressure (used for relief valves and blowdowns)
• ZSTARTP – when true forces PV = PDESIGN, holding drum pressure constant. This is used
for initializing the BoilerSepar to full load.
• ZSTARTF – when true forces VBDP = 0.5*KBDVEQ, holding drum level constant. This is
used for initializing the BoilerSepar to full load.
For more information on how to use the ZSTARTP and ZSTARTF parameters, see the
DrumBoiler Library Documentation.
The following boundary condition parameters can be specified but are not used by the
BoilerSepar:
• Hb - boundary enthalpy (not used)
• Tb - boundary temperature (not used)
• Pb - boundary pressure (not used)
• Xncb - boundary fraction of fluid non-condensibles (not used)
• Qimp - Imposed heat transfer (not used)
The following malfunctions are available for this object:
Description Type Special configuration required
Leakage Variabl yes

e
The header object may be configured to leak. By default, header leaks are disabled to maximize
network solution speed.

BoilerSepar
Guidelines for configuring a Leakage malfunction:
• Set NOLEAK = 0 to enable the leak malfunction.
• Set the JLEAK to the maximum desired leak flow coefficient. Note that head is ignored in
the leak flow calculation.
• Since the pressure solution is a state, enabling leak malfunctions will have no adverse effect
on the complicate the network solution speed.
Examples
Example 1
The following example is the drum from a natural circulation boiler. The drum has seven relief
valves, one blowdown valve, and four vent valves.
• The waterwalls LEFT_WW, REAR_WW, FRONT_WW, and RIGHT_WW (BoilerSurf) and

drum DWNCMR (BoilerDC) objects are not shown. See Example 1 of those classes.
• Only valve VDRUM_BD is shown in detail. None of the other drain valves is shown in this
example.
• Only valve VDC_DRUM1 is shown in detail as representative of all vent valves in this
example.

BoilerSepar
BOILERSEPAR: DRUM
Example drum
Design Operating Conditions
FDESIGN 1189 lb/sec Design Flow
PDESIGN 2685.9 psia Design Pressure
Fluid Properties
FLUID 1 Fluid Type
E 291.5 ft Number of downcomer drains
Downcomer drain valve

LEN 110.54 ft
object connection

BoilerSepar
THK 7.625 in Thickness of piping
Boiler drum inner radius of

KBDR 3 ft
pressure vessel shell
Separator factor that defines

SEPMASFAC 0.87
internal metal mass
Separator fluid volume

correction for internal metal
VOLUMECOR 1.36 This value will increase the

available fluid volume beyond
that calculated by LEN and
KBDR.
Object Connection
Array of references to inlet

OFI 2 size
flow paths
OFI[0] FFW12 Economizer flow
OFI[1] FC12 Fill from condensate
Array of references to exit

OFX 1 size
flow paths
OFX[0] FSH1 Steam flow to superheaters
Object-ObjectConnection

LI 2 size
flow paths
LI[0] 2.0 Economizer flow
LI[1] 2.0 Fill from condensate

LX 1 size
flow paths
LX[0] 6.0 Steam flow to superheaters
Reference to downcomers
ODC 1 size
attached to separator
ODC[0] DWNCMR downcomer object
OSURF 1 size Reference to surfaces attached

BoilerSepar
to separator
OSURF[0] FRONT_WW front waterwall objects
OSURF[1] REAR_WW rear waterwall objects
OSURF[2] RIGHT_WW right waterwall objects
OSURF[3] LEFT_WW left waterwall objects
Relief Valves
KRELIEF 2 size Relief valve sizing factor
(lb/sec)/sqrt(psi-
KRELIEF[0] 0.1204
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[1] 0.1204
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[2] 0.1204
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[3] 0.1204
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[4] 0.1204
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[5] 0.1204
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[6] 0.1204
lb/ft3)
KRELPOP 2 size Relief valve opening pressure
KRELPOP[0] 2950 psia

BoilerSepar
Relief valve reset close

KRELRES 2 size
pressure
The reset pressure is 30 psi

KRELRES[0] 2920 psia
less than the pop pressure
Startup Blowdowns
Number of startup blowdown

NBLOSTART 1
valves
OVBLOSTART 1 size Startup blowdown valve
OVBLOSTART[0] VDRUM_BD Drum blowdown valve
Startup blowdown valve

PBLOSTART 1
downstream pressure
PBLOSTART[0] PAMB
Vent Valves
JVENT 4 size Vent valve flow coefficient
JVENT[0] 1.52
JVENT[1] 1.52
JVENT[2] 1.52
JVENT[3] 1.52
OVVENT 4 size Vent valve
OVVENT[0] VDRUM1
OVVENT[1] VDRUM2
OVVENT[2] VDRUM3

BoilerSepar
OVVENT[3] VDRUM4
VALVES: VDRUM_BD
Example drum blowdown drain valve
TIMEOP 15 sec Time to open
(lb/sec)/sqrt(psi-
lb/ft3)
VALVES: VDRUM1
Example drum vent valve (VDRUM2, VDRUM3, VDRUM4 similar)
(lb/sec)/sqrt(psi-
lb/ft3)
Example 2
The following example is the drum from a forced circulation boiler. The drum has two vent flows
with two valves, one continuous blowdown flow with two valves, and two drain valve flows with
five valves.
• The waterwalls XWWA and XWWB (BoilerSurf) and drum DNCMR (BoilerDC) objects are
not shown. See Example 2 of those classes.
• The economizer heat exchangers HXECONA and HXECONB (HxOTB) objects are not
shown in this example.
• The flow paths are not shown in this example.
• Only the vent valves are shown in this example.

BoilerSepar
BOILERSEPAR: DRUM
Example drum
FDESIGN 1694 lb/sec Design Flow
PDESIGN 2700 psia Design Pressure
Fluid Properties
FLUID 1 Fluid Type
E 330.25 ft Number of downcomer drains
Downcomer drain valve

LEN 431.25 ft
object connection

BoilerSepar
THK 5.00 in Thickness of piping
Boiler drum inner radius of

KBDR 2.75 ft
pressure vessel shell
Object Connection

OFI 5 size
flow paths
OFI[0] FEDV End drum vent flow
OFI[1] FCDV Center drum vent flow
OFI[2] FECONA Economizer A flow
OFI[3] FECONB Economizer B flow
OFI[4] FBF_DRUM Boiler fill flow

OFX 5 size
flow paths
OFX[0] FDCD Continuous blowdown flow
OFX[1] FSH1A Steam flow to superheaters
OFX[2] FSH1B Steam flow to superheaters
OFX[3] FAS2 Steam flow to aux steam
OFX[4] FTANDEM Tandem drain flow
OFX[5] FBURP BWCP burp flow
Object-ObjectConnection

LI 5 size
flow paths
LI[0] 5.0 End drum vent flow
LI[1] 5.0 Center drum vent flow
LI[2] 0.2 Economizer A flow
LI[3] 0.2 Economizer B flow
LI[4] 0.2 Boiler fill flow
LX 1 size Array of references to exit

BoilerSepar
flow paths
LX[0] 0.2 Continuous blowdown flow
LX[3] 5.0 Steam flow to aux steam
LX[4] 0.2 Tandem drain flow
LX[5] 0.2 BWCP burp flow
Reference to downcomers
ODC 1 size
attached to separator
ODC[0] DNCMR downcomer object

OSURF 1 size
to separator
OSURF[0] XWWA waterwall objects, furnace A
OSURF[1] XWWB waterwall objects, furnace B
Relief Valves
KRELIEF 7 size Relief valve sizing factor
(lb/sec)/sqrt(psi-
KRELIEF[0] 0.53
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[1] 0.53
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[2] 0.83
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[3] 0.83
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[4] 0.83
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[5] 0.83
lb/ft3)
(lb/sec)/sqrt(psi-
KRELIEF[6] 0.83
lb/ft3)

BoilerSepar
KRELPOP 7 size Relief valve opening pressure
Relief valve reset close

KRELRES 7 size
pressure
MOVI: VCDV
Example center drum valve in FCDV flow path
FTRELAY 1 Full travel relay option
TIMECL 15 sec Time to close
(lb/sec)/sqrt(psi-
lb/ft3)

BoilerSepar
MOVI: VEDV
Example end drum vent valve in FEDV flow path
FTRELAY 1 Full travel relay option
TIMECL 15 sec Time to close
(lb/sec)/sqrt(psi-
lb/ft3)
Data Entry Window Usage

There is no data entry window for this object.

BoilerSepar
Parameter Table - BoilerSepar

Algorithm Outputs
Description UOM Eq Arr Size Sort Dft Dft
Parameter
Name OK Out
Cls Val
dH Derivative of enthalpy Btu/ No N/A No DF 0.0
lbm/
sec
dM Derivative of fluid lbm/ No N/A No DF 0.0

mass
sec
dP Pressure derivitive No N/A No DF 0.0
dPnc Pnc derivative No N/A No DF 0.0
dPv Pv derivative No N/A No DF 0.0
H Enthalpy Btu/ No N/A No SF 43.0
lbm
M Fluid mass lbm No N/A No SF 0.0
P Header pressure No N/A No SF 0.0
Pnc Non-condensibles No N/A No SF 0.0

partial pressure
Pv Vapor partial pressure No N/A No SF 14.7

or working fluid
Ql Heat transfer loss to Btu/ No N/A No DF 0.0

ambient
sec
T Temperature F No N/A No DF 75.0

BoilerSepar
Boundary Conditions
Parameter
Name OK Out
Cls Val
Hb Boundary enthalpy Btu/ Yes N/A No KF
Only used if HFlag = - lbm

1.
HFlag Enthalpy Flag No N/A No KI 0
0 = State
-1 = Boundary, user
defined
-3 = Enthalpy is forced
to Sat vapor or higher
Pamb Ambient pressure psia Yes N/A No DF PAMB
Pb Boundary pressure Yes N/A No KF
If the user wishes to

attach an equation to
the pressure of a
boundary header
(PFlag = -1), then the
Pb parameter must be
used, otherwise either
P or Pb may be used to
attach a boundary
pressure.
PFlag Pressure calculation No N/A No KI 0

type
0 = auto configure
-1 = boundary
pressure (Set Pb)
-2 = state pressure
Qimp Externally imposed Btu/ Yes N/A No DF 0.0

heat transfer
sec
Tamb Ambient temperature F Yes N/A No DF TAMB
Tb Boundary temperature F Yes N/A No KF
Only used if HFlag = -

1.

BoilerSepar

Parameter
OK Out
Name
Cls Val
Xncb Boundary mass ND Yes N/A No KF

fraction of non-
condensibles
Condensation / Evaporation
Description UOM Eqt Array Sort Dft Dft
Parameter
OK Size Out
Name
Cls Val
Fbdcon Drum condensation lbm/ No N/A No DF 0.0

flow rate
sec
Kbdcond Condensation Yes N/A No KF 0.0

coefficient
Kbdevt Pool evaporation time Yes N/A No KF 3.0

constant
Continuous Blowdowns
Parameter
OK Size Out
Name
Cls Val
Fblocon Boiler drum blow lbm/ No NBLO No DF

continuous down flow
sec CON
Jblocon Continuous blowdown Yes NBLO No KF 0.0

valve flow coefficient
CON
Nblocon Number of continuous No N/A No KI 0.0

blowdown valves
OVblocon Continuous blowdown No None No VB

valve AS
E
If this parameter is
defined, it will take
precedence over any
user defined Jblocon
Pblocon Continuous blowdown psia Yes NBLO No DF PAMB

valve downstream
pressure CON

BoilerSepar

Parameter
OK Size Out
Name
Cls Val
Fdesign Design Flow lbm/ No N/A No KF
Saturated steam or sec

Feedwater
Pdesign Design Pressure psia No N/A No KF
Pressure at normal
operating conditions,
max load. Do NOT
use pressure vessel
design limits
Downcomer/Waterwall Circulation Parameters (Dynamically Calculated

Outputs)
Parameter Description UOM Eqt Array Sort Dft Dft

Name OK Size Out
Cls Val
Fdcvx Rate of downcomer lbm/ No N/A No DF 0.0

steam flow to drum
from DC boiling sec
Hrx Mass avg enth. of flow Btu/ No N/A No DF 0.0

entering separator
from boiler surfaces lbm
Pdci Downcomer inlet psia No N/A No DF 0.0

pressure - includes
drum level static head
Qfld Delayed flashing Btu/ No N/A No DF 0.0

energy to drum from
stability limits sec
Qwwalos Energy transferred in Btu/ No N/A No DF 0.0

dAww limiting
sec
Ssaction Boilertube shrink swell No N/A No KF 0.0

action
0 = to DC
1 = to Separ

BoilerSepar
Vsurge Surge volume from No N/A No DF 0.0

BCP on/off
Wdc Flow from boiler drum lbm/ No N/A No DF 0.0

to the downcomer
sec
Wdcfill Downcomer filling lbm/ No N/A No DF 0.0

flow
sec
Wdclx Rate of downcomer lbm/ No N/A No DF 0.0

liquid displacement
due to stm form in DC sec
Wrxl Total sat water flow lbm/ No N/A No DF 0.0

from boiler surfaces to
separator sec
Wrxs Total sat steam flow lbm/ No N/A No DF 0.0

separator sec
Wrxt Total flow from boiler lbm/ No N/A No DF 0.0

surfaces to separator
sec
Dynamic Tuning
Parameter
Name OK Out
Cls Val
dPType Pressure derivative Yes N/A No KI 0

calculation type
0 = incompressible
1 = compressible
Kcool FOL time constant for Yes N/A No KF 300.0

cool to ambient
Only used if there is no

metal mass or volume
specified
KdPS Multiplier on pressure No N/A No KF 1.0

deriv calcs
To decrease the value

of dP, decrease KdPS
Lag Lag for pressure deriv No N/A No KF 1.0

BoilerSepar

Parameter
OK Out
Name
Cls Val
calcs
UAlS Heat loss to ambient nd Yes N/A No KF 1.0

scale factor
FW Chemistry Model Interface (Dynamically Calculated Outputs)

Parameter
Name OK Size Out
Cls Val
Fsteamtot For fwchem -Sum of lb/sec No N/A No DF 0.0

all steam flows exiting
flow circuit
Masstotal For fwchem -Sum of lb No N/A No DF 0.0

all fluid mass in the
flow circuit
Wblotot For fwchem -Sum of lb/ No N/A No DF 0.0

Fblocon[i] for i=1,n
sec
Wdraintot For fwchem -Sum of lb/ No N/A No DF 0.0

all non-surface drain
flows exiting flow sec
circuit
Fluid Properties
Parameter Description UOM Eq Arr Size Sort Dft Dft

OK Out
Name
Cls Val
Cp Fluid specific heat Btu/ No N/A No KF 1.0
lbm-
Fluid Fluid Type No N/A No KI 0
Any valid fluid type

available with
ESSCOR's fluid
properties data bases
R Density lbm/ Yes N/A No DF 62.4

BoilerSepar

Parameter
OK Out
Name
Cls Val
The NetHdr algorithm ft3

expects R as an input;
however, the Header
derived class will
calculate R for you.
Xnc Mass fraction of non- frac No N/A No DF 0.0

condensables
tion
Ync Mole fraction of non- frac No N/A No DF 0.0

condensables
tion
Geometric Specification
Parameter
OK Out
Name
Cls Val
Cpm Metal specific heat Btu/ No N/A No KF 0.11
lbm-
D Outside diameter in No N/A No KF
E Elevation ft No N/A No KF 0.0
This elevation must be

relative to a reference
common to all headers
in the network
Len Length of piping ft No N/A No KF
Mm Metal mass lbm No N/A No KF
If specified by the user,

this metal mass will be
used in place of the
metal mass calculated
by the D, Len and Thk
parameters
Thk Thickness of piping in No N/A No KF
V Fluid volume ft3 No N/A No KF

BoilerSepar

Parameter
OK Out
Name
Cls Val
If specified by the user,

this volume will be
used in place of the
volume calculated by
the D, Len and Thk
parameters
Geometry Specification (Also use Len and Thk from NSHEADER base class)

OK Size Out
Name
Cls Val
Kbdr Boiler drum inner ft No N/A No KF 3.0

radius of pressure
vessel shell.
Note: Do not use the

"D" parameter of the
HEADER base class
Sepmasfac Separator factor that frac No N/A No KF 0.200

defines internal metal
mass tion
Volumecor Separator fluid volume frac No N/A No KF 0.700

correction for internal
metal tion
Inlet and Exit Flow Conditions (Dynamically Calculated Outputs)

Name OK Size Out
Cls Val
Fbdi Steam entering drum lbm/ No N/A No DF 0.0

bypassing pool to
separator sec
Fbds Steam flow through lbm/ No N/A No DF 0.0

saturated connector
sec
Hbdi Enthalpy of feedwater Btu/ No N/A No DF 0.0

flow to drum
lbm
Lhyd Hydraulic head No N/A No DF 0.0

BoilerSepar
correction for full

drum with incoming
flow
Qsub Subcooled correction No N/A No DF 0.0

to drum entering
energy
Wbdi Feedwater flow to lbm/ No N/A No DF 0.0

drum
sec
Malfunctions
Parameter
OK Out
Name
Cls Val
JLeak Leak flow coefficient (lb/se Yes N/A No KF

c)/
Flow coefficient
magnitude. Pressure sqrt(p
gradient will si-
determine direction. lb/ft3)
NoLeak No leak malfunction No N/A No KI 1

possible flag
0 = Leak malfunction
is possible
1 = Leak malfunction
will never operate on
this object
If there is not a leak

malfunction
requirement, the
header and its flows
may be reducible by
setting this flag to 1.
This will increase
solution speed.

BoilerSepar
Mass Balance
Parameter
Name OK Out
Cls Val
dFdP Sensitivity of flow wrt No N/A No SF 0.0

pressure - last iteration
dFdPAvg Sensitivity of flow wrt No N/A No SF 0.0

pressure - average
Fi Inlet flow rate lbm/ No OFI No DF 0.0
sec
FiLeak Leak flow rate from lbm/ No N/A No DF 0.0

ambient
sec
Fir Reverse inlet flow rate lbm/ No OFI No DF 0.0
sec
Fx Exit flow rate lbm/ No OFX No DF 0.0
sec
FxLeak Leak flow rate to lbm/ No N/A No DF 0.0

ambient
sec
Fxr Reverse exit flow rate lbm/ No OFX No DF 0.0
sec
MassBal Sum of Fi - Sum of Fx lbm/ No N/A No DF 0.0
sec
Ncalls Number of calls per No N/A No KI 0.0

time step
Niters Number of iterations to No N/A No KI 0.0

converge
This is the total

number of iterations
that the header
executed each time
step. For nested
headers, the total
number will be
cumulative from all
solutions with higher
level headers. To

BoilerSepar

Parameter
OK Out
Name
Cls Val
determine the total
number of iterations
per solution, use
NITERS/NCALLS
Metal Heat Transfer Model Configuration

OK Size Out
Name
Cls Val
Nodes Number of drum nodes No N/A No KI 2
Nodesp1 Number of drum nodes No N/A No KI 3

plus 1
Thicfrac Boiler drum cylinder fracti No NODES No KF 0.5

wall thickness fraction on
per node
Metal Heat Transfer Model Tuning Constants (Calculated By Preprocessor)

Parameter
Name OK Size Out
Cls Val
Kbdmbc cylinder metal bottom No NODES No KF 0.0

M*C - preprocessed
Kbdmbk cylinder bottom No NODES No KF 0.0

conduct coeff - prepro. P1
Kbdmic internal metal tune dP No N/A No KF -999

M*C - preprocessed
Kbdmtbk cylinder top to bot No NODES No KF 0.0

conduct coeff - prepro.
Kbdmtc cylinder metal top No NODES No KF 0.0

M*C - preprocessed
Kbdmtk cylinder top conduct No NODES No KF 0.0

coeff - prepro. P1

BoilerSepar
Metal Heat Transfer Model Tuning Constants (Set By User)

Parameter
Name OK Size Out
Cls Val
Kbdmbf cylinder metal bottom Yes N/A No KF -999

Design stm flow
Kbdmbf0 cylinder metal bottom Yes N/A No KF -999

stm 0 flow offset
Kbdmbl cylinder metal bottom Yes N/A No KF -999

loss UA outer node
Kbdmbsnc cylinder metal bottom Yes N/A No KF -999

Nat conv for steam
Kbdmbsua cylinder metal bottom Yes N/A No KF -999

Design UA for steam
Kbdmbw cylinder metal bottom Yes N/A No KF -999

Design wat flow
Kbdmbw0 cylinder metal bottom Yes N/A No KF -999

wat 0 flow offset
Kbdmbwnc cylinder metal bottom Yes N/A No KF -999

Nat conv for water
Kbdmbwua cylinder metal bottom Yes N/A No KF -999

Design UA for water
Kbdmrc riser connector metal Yes N/A No KF 0.0

M*C - opt., 0
deactivates
Kbdmrf riser connector metal Yes N/A No KF -999

Design stm flow
Kbdmrf0 riser connector metal Yes N/A No KF -999

stm 0 flow offset
Kbdmrk riser metal conduct Yes N/A No KF -999

coeff to drum bot
Kbdmrl riser metal loss UA Yes N/A No KF -999

outer node
Kbdmrsnc riser connector metal Yes N/A No KF -999

Nat conv for steam
Kbdmrsua riser connector metal Yes N/A No KF -999

Design UA for steam
Kbdmrw riser connector metal Yes N/A No KF -999

BoilerSepar
Design wat flow
Kbdmrw0 riser connector metal Yes N/A No KF -999

wat 0 flow offset
Kbdmrwnc riser connector metal Yes N/A No KF -999

Nat conv for water
Kbdmrwua riser connector metal Yes N/A No KF -999

Design UA for water
Kbdmsc saturated connector Yes N/A No KF 0.0

metal M*C - opt., 0
deactivates
Kbdmsf saturated connector Yes N/A No KF -999

metal Design stm flow
Kbdmsf0 saturated connector Yes N/A No KF -999

metal stm 0 flow
offset
Kbdmsk sat.con. metal conduct Yes N/A No KF -999

coeff to drum top
Kbdmsl sat. con. metal loss Yes N/A No KF -999

UA outer node
Kbdmspl0 sat.con. pool flooding Yes N/A No KF -999

level onset
Kbdmspl1 sat.con. pool flooding Yes N/A No KF -999

level full effect
Kbdmsplk sat.con. pool flooding Yes N/A No KF 0.0

UA
Kbdmssnc saturated connector Yes N/A No KF -999

metal Nat conv for
steam
Kbdmssua saturated connector Yes N/A No KF -999

metal Design UA for
steam
Kbdmsw saturated connector Yes N/A No KF -999

metal Design wat flow
Kbdmsw0 saturated connector Yes N/A No KF -999

metal wat 0 flow
offset
Kbdmswnc saturated connector Yes N/A No KF -999

metal Nat conv for
water
Kbdmswua saturated connector Yes N/A No KF -999

BoilerSepar
metal Design UA for

water
Kbdmtf cylinder metal top Yes N/A No KF -999

Design stm flow
Kbdmtf0 cylinder metal top stm Yes N/A No KF -999

0 flow offset
Kbdmtl cylinder metal top loss Yes N/A No KF -999

UA outer node
Kbdmtpl0 drum cyl top pool Yes N/A No KF -999

flooding level onset
Kbdmtpl1 drum cyl top pool Yes N/A No KF -999

flooding level full
effect
Kbdmtplk drum cyl top pool Yes N/A No KF 0.0

flooding UA
Kbdmtsnc cylinder metal top Nat Yes N/A No KF -999

conv for steam
Kbdmtsua cylinder metal top Yes N/A No KF -999

Design UA for steam
Kbdmtw cylinder metal top Yes N/A No KF -999

Design wat flow
Kbdmtw0 cylinder metal top wat Yes N/A No KF -999

0 flow offset
Kbdmtwnc cylinder metal top Nat Yes N/A No KF -999

conv for water
Kbdmtwua cylinder metal top Yes N/A No KF -999

Design UA for water
Metal Heat Transfer Rates (Dynamically Calculated Outputs)

Parameter
OK Size Out
Name
Cls Val
Qbdmb Cylinder metal bottom Btu/ No NODES No DF 0.0

heat transfer rate P1
sec
Qbdmi Internal metal heat Btu/ No N/A No DF 0.0

transfer rate
sec
Qbdmr Riser metal to pool Btu/ No N/A No DF 0.0

BoilerSepar
H.T.
sec
Qbdmrl Riser metal loss to Btu/ No N/A No DF 0.0

ambient
sec
Qbdmrs Riser metal to drum Btu/ No N/A No DF 0.0

bot. H.T.
sec
Qbdms Sat. con. metal to Btu/ No N/A No DF 0.0

steam H.T.
sec
Qbdmsl Sat. con. metal loss to Btu/ No N/A No DF 0.0

ambient
sec
Qbdmsp Sat. con. metal to pool Btu/ No N/A No DF 0.0

H.T.
sec
Qbdmss Sat. con. metal to drum Btu/ No N/A No DF 0.0

top H.T.
sec
Qbdmt Cylinder metal top Btu/ No NODES No DF 0.0

heat transfer rate P1
sec
Qbdmtb Boiler drum cylinder Btu/ No NODES No DF 0.0

metal top heat transfer
sec
Qbdmtp H.T. due to flood from Btu/ No N/A No DF 0.0

upper drum shell to
pool sec
Metal Temperatures (Dynamically Calculated Outputs)

Parameter
OK Size Out
Name
Cls Val
dTbdmb Derivative of cylinder F/se No NODES No DF 0.0

metal bottom
c
dTbdmr Derivative of riser F/se No N/A No DF 0.0

connector metal temp
c
dTbdms Derivative of saturated F/se No N/A No DF 0.0

connector metal temp
c

BoilerSepar
dTbdmt Derivative of cylinder F/se No NODES No DF 0.0

metal top
c
Tbdmb Cylinder metal bottom F No NODES No SF 75.0
Tbdmr Riser connector metal F No N/A No SF 75.0

temp
Tbdms Saturated connector F No N/A No SF 75.0

metal temp
Tbdmt Cylinder metal top F No NODES No SF 75.0
Model Setup/First Time Initialization to Full Load Conditions (Do Not Use, Not
Yet Implemented)
Parameter
OK Size Out
Name
Cls Val
Estartf Startup Mode Error No N/A No DF 0.0
Estartp Startup Mode Error No N/A No DF 0.0
Tstartf Startup Mode Timer No N/A No DF 0.0
Tstartp Startup Mode Timer No N/A No DF 0.0
Zstartf Startup Mode Switch No N/A No DI 0.0
When this is true, the

drum will be forced to
be half full
Zstartp Startup Mode Switch No N/A No DI 0.0
When this is true, the

drum vapor pressure
will be at design
Non-condensibles (Dynamically Calculated Outputs)

Parameter
OK Size Out
Name
Cls Val
Fbdai Boiler drum air inlet lbm/ Yes N/A No DF 0.0

flow
sec
Fbdax Boiler drum air exit lbm/ Yes N/A No DF 0.0

BoilerSepar
flow
sec
Yv Volume fraction of frac No N/A No DF 0.0

steam in drum
tion
Object Connections

Name OK Out
Cls Val
OFi Array of references to No None No NE

inlet flow paths TFL
OW
OFx Array of references to No None No NE

exit flow paths TFL
OW
Object-Object Connections
Parameter Description UO Eqt Array Sort Dft Dft

M OK Size Out
Name
Cls Val
Li Level of inlet flow ft No OFI No KF 0.0

piping
This parameter should

be set for every inlet
flow (OFI), and is used
to determine flow
conditions during
reverse flow, based on
drum pool level.
This level is relative to

the bottom of the drum
(L = 0), which is also at
E for the drum.
Lx Level of exit flow ft No OFX No KF 0.0

piping
This parameter should

be set for every exit flow
(OFX), and is used to
determine flow
conditions during
forward flow, based on
drum pool level.

BoilerSepar
Description UO Eqt Array Sort Dft Dft

Parameter
M OK Size Out
Name
Cls Val
This level is relative to

the bottom of the drum
(L = 0), which is also at
E for the drum.
Negative Lx's are valid,
and indicate that the
flow is connected to a
downcomer. The
ODcFx parameter
should be used in
coordination with any
negative Lx.
ODc Reference to No None No BOI

downcomers attached to LE
separator RD
C
A BoilerSepar must have
>= 1 downcomer
attached.
Note that each BoilerDC

attached must have a
reference to one or more
BoilerSurf's (which
must also be attached, to
this BoilerSepar), by
using the OSurf
parameter of BoilerDC
ODcFx Downcomer of exit No None No BOI

flow, if from a LE
downcomer RD
C
Since all exit flows from
the Boiler system must
be connected to
BoilerSepar, it is
necessary to identify
those, which are
actually taken from one
of the downcomers.
This array should be
consistent indexing with
OFX from the NETHDR
base class. A negative
Lx should be used when
ODcFx is used.
OSurf Reference to surfaces No None No BOI

attached to separator LE

BoilerSepar
Description UO Eqt Array Sort Dft Dft

Parameter
M OK Size Out
Name
Cls Val
RS
A BoilerSepar must have UR
>= 1 surface attached. F
Note that each

BoilerSurf attached
must be refered to by
only one BoilerDC,
(which must also be
attached to this
BoilerSepar), by using
the OSurf parameter of
BoilerDC.
Pool Parameters - (Dynamically Calculated Outputs)

Parameter
OK Size Out
Name
Cls Val
Abdp Pool vapor void frac No N/A No SF 0.0

fraction
tion
dAbdp Derivative of Abdp frac No N/A No DF 0.0
tion
/sec
Dmbdperr Error in pool deriv due No N/A No DF 0.0

to volume empty or
full
Dmbdps Pool steam mass ROC lbm/ No N/A No DF 0.0

- not a state
sec
Dmbdpw Pool water mass ROC lbm/ No N/A No DF 0.0

- not a state
sec
Drdhp Pool partial of density No N/A No DF 0.0

to enthalpy
dVbdp Derivative of drum ft3/ No N/A No DF 0.0

pool volume
sec
Dvbubdp Partial of dvbub to No N/A No DF 0.0

pressure at total P

BoilerSepar
Dvfgdp Partial of spec vol No N/A No DF 0.0

vapor-liq to pres - at
total P
Fbdfl Pool flashing rate of lbm/ No N/A No DF 0.0

steam generation
sec
Hbdpi Set equal to Hbdsl No N/A No DF 0.0
L Pool level physical ft No N/A No DF 0.0

from bottom of drum
Mbdps Mass of steam vapor in lbm No N/A No DF 0.0

drum pool
Mbdpw Mass of water liquid in lbm No N/A No DF 0.0

drum pool
Mbds Mass of steam in drum lbm No N/A No DF 0.0

above the pool
Vbdp Pool volume ft3 No N/A No SF 0.0
Vbds Volume available to ft3 No N/A No DF 0.0

steam for dpbds
evaluation
Vbub Pool bubble velocity ft/sec No N/A No DF 0.0
Wbdpi Drum pool net flow lbm/ No N/A No DF 0.0

rate - except liquid
blowdowns sec
Pool Parameters - Advanced Tuning Features

OK Size Out
Name
Cls Val
Kbdphst Limit on dhbdp Yes N/A No KF 100.0

denominator for
stability
Kbdveq Volume of drum cyl. Yes N/A No KF -1.0

which fluid can occupy
- preprocessed
Kbdvfl Flag to keep L const. Yes N/A No KF 0.0

while adj. Vbd to L
relation
Maxpoolv Max pool volume as frac No N/A No KF 0.99

fraction of total

BoilerSepar
tion
Minpoolv Min pool volume as frac No N/A No KF 0.01

fraction of total
tion
Vbdcor Graphical correction to No N/A No DF 0.0

pool volume
Volempty Empty volume below ft3 No N/A No DF 0.0

drum pool
Relief Valves
Parameter
OK Size Out
Name
Cls Val
Arelief Relief valve No KRE No DF 0.0

normalized area
LIEF
Fbdrv Total steam flow lbm/ No N/A No DF 0.0

through drum relief
valves sec
Krelief Relief valve sizing Yes None No KF

factor
Krelpop Relief valve opening psia Yes KRE No KF 0.0

pressure
LIEF
Krelres Relief valve reset close psia Yes KRE No KF 0.0

pressure
LIEF
Srelgag Relief valve gag Yes KRE No DF 0.0

command
LIEF
Srelpow Relief valve power pop Yes KRE No DF 0.0

command
LIEF
Saturation Properties (Dynamically Calculated Outputs)

Name OK Size Out
Cls Val
dTbd Derivative of saturated F No N/A No DF 0.0

BoilerSepar
temperature
corresponding to Pv
Hfg Enthalpy of Btu/ No N/A No DF 0.0

vaporization
lbm
Hfg1 Enthalpy of Btu/ No N/A No DF 0.0

vaporization
lbm
Hldp Partial of sat liquid Btu/ No N/A No DF 0.0

enthalpy to pressure
lbm/
psi
Hldp1 Partial of sat liquid Btu/ No N/A No DF 0.0

enthalpy to pressure
lbm/
psi
Hlsat Saturated liquid Btu/ No N/A No DF 0.0

enthalpy
lbm
Hlsat1 Saturated liquid Btu/ No N/A No DF 0.0

enthalpy
lbm
Hvsat Saturated vapor Btu/ No N/A No DF 0.0

enthalpy
lbm
Hvsat1 Saturated vapor Btu/ No N/A No DF 0.0

enthalpy
lbm
Rldp Partial of sat liquid lbm/ No N/A No DF 0.0

density to pressure
ft3/
psi
Rldp1 Partial of sat liquid lbm/ No N/A No DF 0.0

density to pressure
ft3/
psi
Rlsat Saturated liquid lbm/ No N/A No DF 0.0

density
ft3
Rlsat1 Saturated liquid lbm/ No N/A No DF 0.0

density
ft3

BoilerSepar
Rvdp Partial of sat vapor lbm/ No N/A No DF 0.0

density to pressure
ft3/
psi
Rvdp1 Partial of sat vapor lbm/ No N/A No DF 0.0

density to pressure
ft3/
psi
Rvsat Saturated vapor lbm/ No N/A No DF 0.0

density
ft3
Rvsat1 Saturated vapor lbm/ No N/A No DF 0.0

density
ft3
Tbd Saturated temperature F No N/A No SF 75.0

at Pv
Tsat Saturated temperature F No N/A No DF 0.0
Tsat1 Saturated temperature F No N/A No DF 0.0
Tsdp Partial of saturated F/ps No N/A No DF 0.0

temperature to
pressure i
Tsdp1 Partial of saturated F/ps No N/A No DF 0.0

temperature to
pressure i
Vfg Specific volume ft3/ No N/A No DF 0.0

change of vaporization
lbm
Vfg1 Specific volume ft3/ No N/A No DF 0.0

change of vaporization
lbm
Startup Blowdowns (OFX may also be used to define/connect a startup

blowdown)

OK Size Out
Name
Cls Val
Fblostart Boiler drum start-up lbm/ No NBLO No DF

blowdown flow
sec START
Jblostart Startup blowdown Yes NBLO No DF 0.0

BoilerSepar
valve flow coefficient

START
Nblostart Number of startup No N/A No KI 0

blowdown valves
OVblostart Startup blowdown No None No VB

valve AS
E
If this parameter is
precedence over any
user defined Jblostart
Pblostart Startup blowdown psia Yes NBLO No DF PAMB

valve downstream
pressure START
Vent Valves
Parameter
Name OK Size Out
Cls Val
Fvent Flow rate out of vent lbm/ No NVENT No DF 0.0

valve
sec
Jvent Vent valve flow Yes NVENT No KF 0.0

coefficient
Nvent Number of vent valves No N/A No KI 0.0
OVvent Vent valve No None No VB

AS
If this parameter is E
precedence over any
user defined Jvent
Legend:

BoilerSepar
vector.
FAQ
Q. How do I initialize the BoilerSepar to full load conditions?
A. Use the ZSTARTP and ZSTARTF parameters of the BoilerSepar object. Use the ZSTRTFLO
and VSTRTFLO parameters of the BoilerSurf objects – see BoilerSurf documentation.
When ZSTARTP is true, the drum vapor pressure PV is forced to PDESIGN and drum enthalpy H
is forced to HlSat for PDESIGN.
DYNSIM still calculates the change in drum pressure dP based on the energy input from the
waterwalls. This allows the user adjust the waterwall energy input so that dP is zero and the drum
boiler system is at steady state.
When ZSTARTF is true, the drum level is forced to be 50% full. This allows the drum boiler
system to operate while the user establishes a mass balance in and out of the drum.
Q. I experience a sudden pressure drop in my BoilerSepar object when everything else (fuel flow,
feedwater flow, steam flow) is steady. What happened?
A. This can happened if the circulation rate in the waterwalls is too low. The DrumBoiler system
can become unstable if the circulation rate is less than 4 (the total flow through all of the
BoilerSurf objects divided by the exiting steam flow). If your configuration has a circulation rate
less than 4, consider using the FlashTank with HxOTB objects instead of the DrumBoiler library
objects. See the BoilerSurf documentation for information about how to adjust the circulation
flowrate. See DrumBoiler library documentation for a discussion of circulation rate.
This can also be alleviated by setting the KBDCOND parameter to 0. This will disable a certain
condensation calculation inside the pressure/temperature solution.

BoilerSurf
BoilerSurf
Introduction
BoilerSurf extends ModelObject
The BoilerSurf class models the boiler heat exchanging surfaces (or waterwalls) in a drum boiler
system. The base of the boiler waterwalls receives water from the boiler drum through the
downcomer. This class simulates the following:
• The fluid volume and metal mass of the waterwalls
• The heat transfer from furnace flue gases to the waterwalls
• The formation and rise of bubbles in the boiling section of the waterwalls
The solution of the BoilerSurf algorithm is coordinated with the BoilerSepar and BoilerDC
Fundamentals
Single-Phase vs. Two-Phase

The BoilerSurf class models the volume of piping (waterwalls) that receives heat from the furnace
and conveys liquid from a BoilerDC object (at its bottom) to the BoilerSepar (at its top).
Boiling/evaporation occur in the waterwalls. The BoilerSurf calculates the bulk liquid flow rate
through the waterwalls and calculates the formation of steam bubbles and the steam bubble void
fraction in the waterwalls. In the diagram below, the single-phase region (subcooled) is denoted
by “1p” and the two phase region is denoted by “2p”.
Control volume coordinate system oriented along the length of the tube. In this case, the
coordinate system is oriented vertically.

BoilerSurf
For Each Control Volume
The furnace waterwalls are modeled as a predetermined number of parallel tubes. Each tube is
divided into a predetermined number of control volumes. Control volumes are generally selected
so that each node is of constant cross sectional area, tube thickness, etc. The following equations
are valid for each control volume.
coordinate system is oriented at an angle.

BoilerSurf
The tube metal energy equations are written for each control volume as:
dTmmw/dt = (Qwwg – Qwwml – Qwwma) / Kwwm / Kwwccor

where:
dTmmw/dt = change in WW metal temperature (F/sec)
Tmmw = WW metal temperature (F)
Kwwm = WW thermal inertia (Btu/F)
Kwwccor = WW scale factor
Qwwg = Heat transfer from gas to metal heat (radiative and convective)
supplied from the furnace model (Btu/sec)
Qwwml = Heat transfer from metal to fluid (Btu/sec)
Qwwma = Heat transfer from metal to ambient (Btu/sec)
Heat transfers Qwwml and Qwwma are calculated from:
Qwwml = Kml * (Tmmw - Twwl) * Kwwccor

Qwwma = Kma * (Tmmw - Tamb) * Kwwccor

BoilerSurf
where:
Kml = overall thermal conductance (metal to fluid)
Kma = overall thermal conductance (metal to ambient)
Twwl = Fluid temperature (F)
Tamb = Ambient temperature (F)
On the tube side fluid, the mass and energy balance equations depend on whether the fluid is
subcooled liquid or two phase. For control volumes containing subcooled liquid, the energy
balance is written as:
dHsc/dt = [Qwwml + Wwwr * (Hin - Hsc)] / Rsc / Vsc

where:
dHsc/dt = Change in enthalpy in the control volume (Btu/lb/sec)
Hsc = Enthalpy of liquid in the control volume (Btu/lb)
Wwwr = Flow rate of liquid (lb/sec)
Hin = Inlet enthalpy from upstream control volume (Btu/lb)
Rsc = Density of liquid (lb/ft3)
Vsc = Fluid control volume (ft3)
The mass balance assumes incompressible fluid but accounts for thermal expansion or contraction
of the liquid by calculating:
dMsc ∂Rsc dHsc

= Vsc
dt ∂Hsc dt
and summing dMsc/dt for all control volumes for purposes of determining contributions to shrink
and swell effects.
For the two phase control volumes, the energy balance is written as:
Qwwml ∂Rv dΡ
+ RvVg i Α iα i − RvVgΑα − ΑLα
dα Hfg ∂Ρ dt
=
dt RvΑL
where:

BoilerSurf
α = void fraction by volume, Aww[i] (dimensionless)

Hfg = heat of vaporization (Btu/lb)
Rv = density of saturated vapor (lb/ft3)
A= cross sectional area of control volume (ft2)
Vg = velocity of steam in control volume (ft/sec)
L = control volume length, Kwwsln[i] (ft)
Vgi, Ai, α i = Vg, A, α from previous control volume
Compressibility is important in the two phase region thus the rate of change of mass is written as:
dM 2 p ∂M 2 p dα ∂M 2 p dΡ
= +
dt ∂α dt ∂Ρ dt
∂M 2 p
= (Rv − R )ΑL
∂α
∂M 2 p  ∂Pv ∂R 
= α + (1 − α )  AL
∂P  ∂P ∂P 
where:
R = density of saturated liquid
dM 2 p
= rate of change of overall mass (liquid and vapor)
dt
For all two phase control volumes, dM2p/dt is summed to account for compressibility and thermal
expansion or contraction effects in the two phase region.
The mass and energy balances described above require that Wwwr, Vg, and Lsc (location of the
boiling boundary) be known. The flow of liquid through the subcooled region is the bulk flow
rate Wwwr through the water walls. In the two phase region, liquid and steam velocities are
assumed to be related by the bubble velocity, Velbub, according to:

BoilerSurf
Vg = Vel + Velbub
Wwwr − αRvVelbub
Vel =
Α[(1 − α )R + αRv]
where
Vg = velocity of steam in control volume (ft/sec)
Vel = velocity of liquid in control volume (ft/sec)

Velbub = velocity of bubbles in control volume (ft/sec)
thereby leaving bulk flow rate, Wwwr, and boiling boundary location, Lsc, to be determined.
For Each Parallel Tube
The following equations are valid for each parallel tube.
To calculate Wwwr and Lsc, first express the pressure difference from the bottom of the
waterwalls to the top, ∆Pwwt, as the sum of five pressure losses due to:
∆Pwwt = ∆Pscst + ∆Pscd +∆P2pst + ∆P2pd + ∆P2pa

where:
∆Pscst = static head of subcooled length (psid)
∆Pscd = flow squared pressure drop along subcooled length (psid)
∆P2pst = static head of two phase length (psid)
∆P2pd = flow squared pressure drop along two phase length (psid)
∆P2pa = acceleration pressure drop along two phase length (psid)
First pressure loss, the static head of the subcooled length, ∆Pscst, is given by:
Nsc
Rsci ∆Zi
∆Pscst = ∑
i =1 144
where:
Nsc = number of subcooled control volumes

BoilerSurf
Rsci = density of subcooled control volume (lb/ft3)
∆Zi = height of control volume, KwwsHt[i] (ft)
Second pressure loss, the flow squared pressure drop along subcooled length, ∆Pscd, is given by:
2
Nsc JsciWwwr
∆Pscd = ∑
i =1 Rsci Ai
2
Jsci = Kfricfact * 6 / Ktubediam / Kcon

where:
Ai = cross sectional area of control volume (ft2)
Kfricfact = friction factor
Ktubediam = tube diameter (in)
Kcon = (32.174) (144)
Third pressure loss, the static head of two phase length, ∆P2pst, is given by:
N2p
R2 pi ∆Zi
∆P2pst = ∑
i =1 144
R2pi = α i Rv + (1 − α i )R
where:
N2p = number of two phase control volumes
α i = void fraction by volume of control volume
Rv = density of vapor (lb/ft3)

R = density of liquid (lb/ft3)
Fourth pressure loss, the flow squared pressure drop along two phase length, ∆P2pd, is given by:
dPf
N2p Φ i2
∆P2pd = ∑
i =1
dL
R2 pi A 2i
Φ i2 = 1 + Xrxi * ( R / Rv − 1)

BoilerSurf
dPf/dLi = Kfricfact * 6 / Ktubediam / Kcon

where:
Φ i2 = Two phase friction pressure drop multiplier, Phisq[i]
Xrxi = Mass fraction of vapor exiting control volume
Fifth pressure loss, the acceleration pressure drop along two phase length, ∆P2pa, is given by:
N2p
Xrxi − Xrxi −1
∆P2pa = ∑
i =1 KconAi2
The term ∆Pwwt is a function of downcomer conditions and the circulating water pumps.
In general, the terms on the right-hand side of the equation can be written as:
∆Pwwt = f1 (Lsc, Wwwr, Hsci)
Since the Hsci (i=1, Nsc) are states, a second equation relating Lsc and Wwwr is needed.
The second equation is found by recognizing that the enthalpy at the outlet of the last subcooled
control volume should equate to the enthalpy of saturated liquid at the local pressure, or
conversely:
Pwwb = Psath  (HscNsc).
The pressure at the boiling boundary Pwwb should equal drum pressure, Pbd, plus the pressure
losses across the two phase length. This is expressed as:
Pwwb = Pbd + ∆P2pst +∆P2pd + ∆P2pa
This can be written in general as:
Pwwb = f2 (Pbd, αi, Lsc, Wwwr)

BoilerSurf
where αi (i = 1, N2p) and Pbd are states.
This forms two equations and two unknowns, Wwwr and Lsc. To solve, they are first recast in the
form:
G1(Lsc, Wwwr, Hsci) = ∆Pwwt - f1
G2(Pbd, αi , Lsc, Wwwr) = Pwwb - f2
and then differentiated to obtain a two by two matrix:
∂G1 dWwwr ∂G1 dLs Nsc

∂G1 dHsci
+ = −G1 − ∑
∂Wwwr dt ∂Lsc dt i =1 ∂Hsci dt
∂G2 dWwwr ∂G2 dLsc ∂G2 ∂Pbd Nzp ∂G2 dα i

+ = −G2 − −∑
∂Wwwr dt 2 Lsc dt ∂Pbd dt i =1 ∂α i dt
which can be solved for dWwwr/dt and dLsc/dt.
It should be noted that the boiling boundary disappears and the G2 equation is dropped when all
control volumes are subcooled. This results in a single equation for dWwwr/dt. These equations
are solved for each parallel tube simulated.
Specifying Geometry
Boiler tubes may be vertical or may be at an angle.
coordinate system is oriented at an angle.

BoilerSurf
Boiler Surface Geometry configuration
• Specify, Kwwsln[i], the water wall node length for each node, i.
• Specify, Kwwsht[i], the water wall node height for each node, i.
• Specify the number of tubes, Ktubenum.
• Specify the tube wall thickness, Kwallthk. All tubes and all nodes are this thickness.
• Specify the tube wall diameter, Ktubediam. All tubes and all nodes are this diameter.
• Specify the wall span, Kwallspan. This is the width of the furnace wall span in feet.
Guidelines for Configuring Boiler Surface Geometry
• Each node length, Kwwsln[i], must be greater than or equal to twice the minimum two phase
length, Kwwltr.
• Each node height, Kwwsln[i], must be greater than or equal to the node height, Kwwsht[i].
• The tube diameter, Ktubediam, must be greater than 2.1 times the tube wall thickness,
Kwallthk.

BoilerSurf
Because each node has a configurable length and height, it is possible to configure some of the
nodes at an angle and some vertical as shown below.
Uncovered Tubes & Reverse Flow

After the boiler is filled with liquid, the upper portions of the tubes are uncovered. The uncovered
tube portions connect the top of the waterwalls to the top of the drum. As the boiler is fired and
circulation begins, fluid flows through the tubes to the drum and the tubes become completely
covered.
Reverse flow is calculated under the following conditions:
• The uncovered tube length is greater than zero (Lwwuc > 0)
• There is no exit flow (Wwwr = 0)
• The design reverse flow, Kwwrevd, is non-zero
• The design uncovered length, Kwwucdr, is non-zero
If the above conditions are satisfied, then the Reverse flow, Wwwrev, is given by:

BoilerSurf
Wwwrev = Kwwrevd * MAX( 0.1, Lwwuc / Kwwucdr)
If the Minimum circulation rate, Kwwrmn2, is specified, then reverse flow will not be calculated.
Reverse flow functions similarly to Kscmin, minimum circulation used in dHsc calculation, in that
it ensures thermal communication between BoilerSurf nodes when there is no flow.
Orifice Pressure Drop

The user can specify a pressure drop to be calculated across the waterwall orifices by specifying
the parameter Kwworif. The pressure drop is calculated as follows:
dPorif = (Wwwr/KaFlow)^2 * Kwworif / Rsc / 144 / 32.2
where
KaFlow = the flow area of all tubes in the object (ft2) – calculated by preprocessor
Rsc = density of subcooled fluid entering waterwalls (lbm/ft2)
Specifying Tuning Factors

There are number of advanced tuning factors available to influence the response of the BoilerSurf
objects in the Drum Boiler system. See the table below.
Parameter Description When/How to Use
Kamult Flow area multiplier of last This simulates the unheated portion of the last segment
segment that returns to the drum.
Kawwpfac Sensitivity scalar on dAww This is the soda can effect. Reduce pressure and bubbles
for Dpbd form. Increase pressure and bubbles disappear. The
larger the scalar, the greater the formation of steam
bubbles for a given increase in drum pressure.
Kawwfac Gain on dAww Simple scalar. The larger the scalar, the faster the
formation of steam bubbles from heating.
Kl2p Two phase boundary Simple scalar. The smaller the scalar, the slower the
movement damping factor change in movement of the two phase boundary. Use to
increase stability.
Kwwltr Minimum two phase length This is the minimum length of boiling in the tube.
Flashing in the tube or drum occurs to ensure this
minimum. Twice this factor is the minimum length of the
subcooled section. The two phase section is not allowed

BoilerSurf
to be the entire length of the tube.
Kwwrmn Minimum circ rate where This is the minimum flow rate used for change in
friction factor is modified pressure calculations that affect the change in two phase
length, dL2p. The flow rate, Wwwr, is allowed to be less
than Kwwrmn
Kwwrmn2 Minimum circulation rate This is the minimum flow rate. The flow rate, Wwwr, is
limited to this value.
Kwwkma Metal to ambient UA heat Simple scalar. The larger the scalar, the more the heat
loss factor loss to ambient for a given temp difference.
KReset Resets ERROR message These ERROR messages are written when Aww >
counter Kawwlim. After a predetermined number of messages
have been written, no more will be written.
Kwworif Orifice pressure loss A non-zero value will result in a non-zero value for the
coefficient orifice pressure drop, dPorif, and increase the overall
pressure drop across the waterwalls. Tune Kwworif at
full load.
Kscmin Minimum circulation used in This minimum value ensures thermal communication
dHsc calculation between BoilerSurf nodes when there is no flow.
Kwwrevd Design reverse flow rate Design reverse flow rate at design uncovered length,
Kwwucdr. To disable reverse flow, set this to zero.
Kwwucdr Uncovered length at design If there is no forward flow and there is an uncovered
reverse flow length, then the reverse flow is the design reverse flow
scaled by the ratio of uncovered length to design
uncovered length.
Kmwwucfg Scale factor on sensitivity of As the uncovered length decreases, liquid is drawn from
dMwwuc to dLwwuc the boiler drum pool. The larger the scalar, the more the
liquid is removed from the boiler drum pool for a given in
dLwwuc.
Kwwccor Array of scale factor on ww This scales the heat transfer from metal to liquid,
node size - both mass and Qwwml, and metal to ambient, Qwwma, and the rate of
UA change of metal temp, dTwwm. The larger the scalar, the
greater the value of Qwwml and Qwwma for a given
temp difference but the smaller change in dTwwm.
Kmassmult Multiplier for metal mass Simple scalar. The larger the scalar, the greater the
applied to all segments calculated mass of each segment (node).
Kuascale Multiplier on theoretical Simple scalar. The larger the scalar, the greater the heat
conduction for tube to fluid transfer to each segment (node).
Kfricfact Tube friction factor This affects the pressure drop through the waterwalls and
the fluid flow rate. A greater friction factor means a
larger pressure drop and a smaller fluid flow rate.
Kwallspan Wall span - enter 0 for tube This value is used to calculate the mass per unit length of
bundles waterwall tube.

BoilerSurf
Boiler Object Connections

The BoilerSurf object itself has no object connection parameters that must be specified. All of the
object connections between the three classes occur in BoilerSepar and BoilerDC. See the
documentation for those object classes.
There are no boundary conditions that can be specified for this object. BoilerSurf uses the Tamb
of its BoilerSepar.
There are no preconfigured malfunctions are available for this object; however, it is possible to
configure a tube leak malfunction by specifying Kleak and Aleak parameters. Either use a
CustomAnalogMalf object to drive Aleak or use a Simple Valve object to drive Aleak.
Guidelines for configuring a Tube Leak malfunction:
• Set KLEAK, the maximum leak flow coefficient.
• Set ALEAK, the normalized leak area. Either set ALEAK = “CustomAnalogMalf.Out” or set
ALEAK = “ValveS.A”.
• Connect the leak flow rate WLEAK to the furnace. This is not done automatically. It must be
configured manually. See the Furnace documentation for examples.

BoilerSurf
Examples
Example 1
The following example is the downcomer from a natural circulation boiler.
This example has no boiler circ pumps. The downcomer has two drains and two economizer
recirc valves.
• The downcomer DWNCMR (BoilerDC) and drum DRUM (BoilerSepar) objects are not
shown. See Example 1 of those classes.
• Only surfaces LEFT_WW and FRONT_WW are shown in detail as representative of all four
surfaces in this example. Surface RIGHT_WW is similar to LEFT_WW and surface
REAR_WW is similar to FRONT_WW.
• The surface FRONT_WW contains a tube leak malfunction. The parameter ALEAK is
connected to the point MALF[31] through an equation. The value and effect of MALF[31]
varies as follows:
value effect
<0 leak inactive
>0 leak active
=1 leak at
maximum
• None of the valves is shown in this example.

BoilerSurf
BOILERSURF: LEFT_WW
Example waterwall left side surface
KFRICFACT 0.1 Tube friction factor
Multiplier for metal mass

KMASSMULT 0.3
applied to all segments
Wall span - enter 0 or negative

for tube bundles
KWALLSPAN 51 ft
The furnace is 82 ft wide by 51
ft deep
KTUBEDIAM 2.5 in Tube outer diameter

BoilerSurf
Number of tubes
KTUBENUM 203
side wall
KWALLTHK 0.35 in Tube wall thickness
KWWSHT 9 size Water wall node height
KWWSHT[0] 26 ft elev 106’ -> 132.5’
KWWSHT[1] 13 ft elev 132.5’ -> 145’
KWWSHT[2] 10 ft elev 145’ -> 155’
KWWSHT[3] 12 ft elev 155’ -> 167’
KWWSHT[4] 11 ft elev 167’ -> 178’
KWWSHT[5] 28 ft elev 178’ -> 206’
KWWSHT[6] 22.5 ft elev 206’ -> 228.5’
KWWSHT[7] 50 ft elev 228.5’ -> 278.5’
elev 278.5’ -> 291.5’

KWWSHT[8] 13 ft
Unheated length to drum
KWWSLN 9 size Water wall node length
KWWSLN[0] 26 ft elev 106’ -> 132.5’
KWWSLN[1] 13 ft elev 132.5’ -> 145’
KWWSLN[2] 10 ft elev 145’ -> 155’
KWWSLN[3] 12 ft elev 155’ -> 167’
KWWSLN[4] 11 ft elev 167’ -> 178’
KWWSLN[5] 28 ft elev 178’ -> 206’
KWWSLN[6] 22.5 ft elev 206’ -> 228.5’
KWWSLN[7] 50 ft elev 228.5’ -> 278.5’
elev 278.5’ -> 291.5’

KWWSLN[8] 13 ft

BoilerSurf
BOILERSURF: FRONT_WW
Example waterwall front side surface
KFRICFACT 0.1 Tube friction factor
Multiplier for metal mass

KMASSMULT 0.3
applied to all segments

for tube bundles
KWALLSPAN 82 ft
The furnace is 82 ft wide by 51
ft deep
Boiler Surface Leak
Boiler leak modulation -

ALEAK EQUATION typically tied to malfunction
Equation: LIM01(MALF[31])
Boiler leak worst case flow

(lb/sec)/sqrt(psi- coefficient
KLEAK 0.436
lb/ft3)
This should equate to ~ 50 pps
Number of tubes
KTUBENUM 327
front wall and rear wall
KWWSHT[0] 26 ft elev 106’ -> 132.5’
KWWSHT[1] 13 ft elev 132.5’ -> 145’
KWWSHT[2] 10 ft elev 145’ -> 155’
KWWSHT[3] 12 ft elev 155’ -> 167’

BoilerSurf
KWWSHT[4] 11 ft elev 167’ -> 178’
KWWSHT[5] 28 ft elev 178’ -> 206’
KWWSHT[6] 22.5 ft elev 206’ -> 228.5’
KWWSHT[7] 50 ft elev 228.5’ -> 278.5’
elev 278.5’ -> 291.5’

KWWSHT[8] 13 ft
KWWSLN[0] 34 ft sloped hopper region
KWWSLN[1] 13 ft elev 132.5’ -> 145’
KWWSLN[2] 10 ft elev 145’ -> 155’
KWWSLN[3] 12 ft elev 155’ -> 167’
KWWSLN[4] 11 ft elev 167’ -> 178’
KWWSLN[5] 28 ft elev 178’ -> 206’
KWWSLN[6] 22.5 ft elev 206’ -> 228.5’
KWWSLN[7] 50 ft elev 228.5’ -> 278.5’
elev 278.5’ -> 291.5’

KWWSLN[8] 13 ft
Example 2
The following example is the downcomer from a forced circulation boiler.
This example has 4 boiler circ pumps. They are configured to “burp” and use logic blocks to
model the “burp”. The pump burp model reproduces drum level burp diagram in the
Fundamentals section. The pump burp model uses latches and timers to remove a certain amount
of water from drum (via a drain) so that the drum level permanently drops for each burp.
This example has one economizer recirc valve and two drains that are used to remove flow for
waterwall leak malfunctions.
• None of the motors, valves, latches, timers, or flow paths is shown in this example.

BoilerSurf
• The downcomer DNCMR (BoilerDC) and drum DRUM (BoilerSepar) objects are not shown.
See Example 2 of those classes.
• Only waterwall XWWA is shown in detail as representative of both waterwalls in this

example.
BOILERSURF: XWWA
Example waterwall A side surface
Gain on dAww
KAWWFAC 2
enhance drum swell

for tube bundles
KWALLSPAN 154 ft side A is 52ft wide x 50 ft deep
span = front+side+rear =
52+50+52= 154 ft
KWWORIF 70 Orifice pressure loss coefficient
Minimum circ rate where

KWWRMN 2 ft
friction factor is modified
Minimum circulation rate

KWWRMN2 2 ft
ensures minimum flow rate
Number of tubes
KTUBENUM 985
total tubes for A side
KWWSHT[0] 34.9 ft
KWWSHT[1] 52 ft

BoilerSurf
KWWSHT[2] 30 ft
KWWSHT[3] 32 ft
KWWSHT[4] 54 ft
KWWSLN[0] 34.9 ft
KWWSLN[1] 52 ft
KWWSLN[2] 30 ft
KWWSLN[3] 32 ft
KWWSLN[4] 54 ft
Parameter Table - BoilerSurf

Parameter
OK Out
Name
Cls Val
Kamult Flow area multiplier Yes N/A No KF 2.0

of last segment
Kawwfac Gain on dAww Yes N/A No KF 1.0
Kawwlim Upper limit on Aww Yes N/A No KF 0.95

to maintain node
stability
Kawwlim Upper limit on Aww Yes N/A No KF 0.95

to maintain node
stabililty
Kawwpfac Sensitivity scalar on Yes N/A No KF 1.0

dAww for dPbd
Kfricfact Tube friction factor Yes N/A No KF 0.025
Kl2p Two phase boundary Yes N/A No KF 1.0

movement damping
factor
Kmassmult Multiplier for metal Yes N/A No KF 1.0

mass applied to all

BoilerSurf

Parameter
OK Out
Name
Cls Val
segments
Kmwwucfg Scale factor on Yes N/A No KF 1.0

sensitivity of
dMwwuc to dLwwuc
Kreset Resets ERROR Yes N/A No KF 1.0

message counter
Kscmin Minimum circulation Yes N/A No KF 100.

used in dHsc
calculation
Kuascale Multiplier on Yes N/A No KF 1.0

theoretical conduction
for tube to fluid
Kwallspan Wall span - enter 0. or ft Yes N/A No KF 0.0

negative for tube
bundles
Kwallspan Wall span – enter 0 or Yes N/A No KF 0.0

negative for tube
bundles
Kwwccor Array of scale factor Yes KWW No KF 1.0

on ww node size -
both mass and UA SHT
Kwwkma Metal to ambient UA Yes N/A No KF 1.0

heat loss factor
Kwwltr Minimum two phase Yes N/A No KF 1.0

length
Kwworif Orifice pressure loss Yes N/A No KF 0.0

coefficient
Kwwrevd Design reverse flow lbm/ Yes N/A No KF 1000.

rate
sec
Kwwrmn Minimum circ rate Yes N/A No KF -999

where friction factor
is modified
Kwwrmn2 Minimum circulation Yes N/A No KF -999

rate
Kwwucdr Uncovered length at ft Yes N/A No KF 1.0

design reverse flow

BoilerSurf
Algorithm Parameters (Dynamically Calculated)

Parameter
OK Out
Name
Cls Val
Dm2p Flow correct due to lbm/ No N/A No DF 0.0

ww 2p mass
sec
Dmsc Flow correction due to lbm/ No N/A No DF 0.0

ww 1p mass
sec
Dmww Flow correction due to lbm/ No N/A No DF 0.0

ww 2p boundary
movement sec
Dmwwuc Mass r.o.c. due to lbm/ No N/A No DF 0.0

waterwall uncovering
sec
Dpbcwp Circulating pump psid No N/A No DF 0.0

pressure rise
Dpbcwpdw Circulating pump psi/ No N/A No DF 0.0

pressure rise
sensitivity to flow lbm/
sec
Dpdch Static head of psi/ No N/A No DF 0.0

downcomer water
column rate of change sec
Dpdcst Static head of psi No N/A No DF 0.0

downcomer water
column
Dphisqdp Sensitivityof PHISQ to No KWW No DF 0.0

press of boiler drum
SHT
Dporif Pressure drop across psid No N/A No DF 0.0

water wall orifices
Dr2pdp Sensitivity of mass lbm/ No KWW No DF 0.0

average density of
fluid in tube to press ft3/ SHT
psi
Dxrxdp Sensitivityof Xrx to No KWW No DF 0.0

press of boiler drum
SHT
Hhdi Downcomer enthalpy Btu/ No N/A No DF 43.0

BoilerSurf

Parameter
OK Out
Name
Cls Val
lbm
M2ps Mass of steam in two lbm No N/A No DF 0.0

phase region
M2pw Mass of water in two lbm No N/A No DF 0.0

phase region
Msc Mass of water in single lbm No N/A No DF 0.0

phase region
Phd Waterwall inlet psia No N/A No DF 0.0

pressure
Phisq Two phase friction No KWW No DF 0.0

pressure drop
multiplier SHT
Qflat Delayed flashing Btu/ No N/A No DF 0.0

energy from stability
limits sec
Qfld Delayed flashing Btu/ No N/A No DF 0.0

energy to drum from
stability limits sec
Qflt Delayed flashing Btu/ No N/A No DF 0.0

energy from stability
limits sec
Qwwalos Energy transferred in Btu/ No N/A No DF 0.0

dAww limiting
sec
Qwwat Sum heat transfer to Btu/ No N/A No DF 0.0

ambient for all nodes
sec
Qwwgt Sum heat transfer from Btu/ No N/A No DF 0.0

gas to metal for all
nodes sec
Qwwlt Sum heat transfer from Btu/ No N/A No DF 0.0

metal to liquid for all
nodes sec
R2p Mass average density lbm/ No KWW No DF 0.0

of fluid in tube
ft3 SHT
Twwl Fluid temperatures F No KWW No DF 75.0

inside tubes

BoilerSurf

Parameter
OK Out
Name
Cls Val
SHT
Vg Summation of bubble ft/sec No KWW No DF 0.0

velocity and bulk fluid
velocity SHT
Wwwrev Water wall reverse lbm/ No N/A No DF 0.0

flow - currently not
active sec
Xfull Fraction volume full frac No N/A No DF 0.0
tion
Xrx Mass fraction of frac No KWW No DF 0.0

vapour exiting tube
element tion SHT
Boiler Surface Leak

Parameter
OK Out
Name
Cls Val
Aleak Boiler leak modulation Yes N/A No DF 0.0

- typically tied to
malfunction
Kleak Boiler leak worst case Yes N/A No KF 0.0

flow coefficient
Wleak Boiler leak flow - lbm/ No N/A No DF 0.0

assumed ww inlet
enthalpy sec
Exit Flow To Separator

Parameter
OK Out
Name
Cls Val
Hrx Mass avg enthalpy of Btu/ No N/A No DF 0.0

flow entering separator
from boiler surfaces lbm
Wrxl Total sat water flow lbm/ No N/A No DF 0.0

separator sec

BoilerSurf
Wrxs Total sat steam flow lbm/ No N/A No DF 0.0

separator sec
Wrxt Total flow from boiler lbm/ No N/A No DF 0.0

surfaces to separator
sec
Fluid States
Parameter
OK Out
Name
Cls Val
Aww Void fraction frac No KWW No SF 0.0
tion SHT
dAww Derivative of void frac No KWW No DF 0.0

fraction
tion SHT
/sec
dHsc Derivative of tube Btu/ No KWW No DF 0.0

fluid enthalpy
lbm/ SHT
sec
dL2p Derivative of two ft/sec No N/A No DF 0.0

phase length
dLwwuc Derivative of ft/sec No N/A No DF 0.0

uncovered length in
boiler tubes
dPwwb Derivative of pressure psi/ No N/A No DF 0.0

at boiling boundary
sec
dTwwm Derivative of tube F/sec No KWW No DF 0.0

metal temperatures
SHT
dWwwr Derivative of lbm/ No N/A No DF 0.0

Circulation flow rate
sec/
sec
Hsc Tube fluid enthalpy Btu/ No KWW No SF 43.0
lbm SHT

BoilerSurf

Parameter
OK Out
Name
Cls Val
L2p Two phase length ft No N/A No SF 0.0
Lwwuc Uncovered length in ft No N/A No SF 0.0

boiler tubes
Pwwb Pressure at boiling psia No N/A No SF 14.7

boundary
Twwm Tube metal F No KWW No SF 75.0

temperatures
SHT
Wwwr Circulation flow rate lbm/ No N/A No SF 0.0
sec
Gas Side Interface

Parameter
OK Out
Name
Cls Val
Qwwg Heat transfer from Btu/ Yes KWW No DF 0.0

heating fluid to metal
sec SHT
Geometry (Calculated in Pre-processor)

Name OK Out
Cls Val
Kaflow Flow area of all tubes No N/A No KF -1

in this bank -
preprocessed
Kpadl Pressure drop factor No N/A No KF -1.

for fluid acceleration -
preprocessed
Kpfdl Friction factor over No N/A No KF -1

diameter -
preprocessed
Kwwc Metal thermal No N/A No KF -1

capacitance -
preprocessed

BoilerSurf
Kwwhlt Total height of all No N/A No KF -1

nodes - preprocessed
Kwwks Conduction coefficient No N/A No KF -999

from metal to fluid -
preprocessed
Kwwllt Total length of all Yes N/A No KF 0.0

nodes - preprocessed
Kwwtnr Tube number ratio - No N/A No KF 1.0

preprocessed
Parameter
OK Out
Name
Cls Val
Ktubediam Tube outer diameter in Yes N/A No KF 2.50
Ktubenum Number of tubes Yes N/A No KF 1000
Kwallthk Tube wall thickness in Yes N/A No KF 284
Kwwsht Water wall node height ft Yes None No KF
Kwwsln Water wall node length ft Yes KWW No KF 0.0
SHT
Onetime Startup Stabilizer Not Yet Implemented

Parameter
OK Out
Name
Cls Val
Estrtflo Start Up Override No N/A No DF 0.0

Error
Estrtl2p Start Up Override No N/A No DF 0.0

Error
Estrtpww Start Up Override No N/A No DF 0.0

Error
Tstrtflo Start Up Override No N/A No DF 0.0

Timer
Tstrtl2p Start Up Override No N/A No DF 0.0

Timer

BoilerSurf
Tstrtpww Start Up Override No N/A No DF 0.0

Timer
Vstrtflo Start Up Override No N/A No DF

Value
Vstrtl2p Start Up Override No N/A No DF

Value
Vstrtpww Start Up Override No N/A No DF

Value
Zstrtflo Start Up Override No N/A No DF 0.0

Switch
Zstrtl2p Start Up Override No N/A No DF 0.0

Switch
Zstrtpww Start Up Override No N/A No DF 0.0

Switch
Legend:
vector.

BoilerSurf
FAQ
Q. During startup I am having trouble establishing natural circulation flow through the
boiler when I begin to fire. How can I address this?
A. Set KwwRMN and KwwRMN2 to ensure proper minimum flow rate during startup. This is
important for low recirculation rate conditions.

Invensys Systems, Inc.
26561 Rancho Parkway South
Lake Forest, CA 92630
United States of America
http://iom.invensys.com
Global Customer Support
Inside U.S.: 1-866-746-6477
Outside U.S.: 1-508-549-2424 or contact your
local Invensys Representative.
Email: iom.support@invensys.com
Website: http://support.ips.invensys.com

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© 2016 by Schneider Electric Software, LLC. All rights reserved.

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Schneider Electric Software, LLC

Specifying Geometry ............................................................................... 93

Class Typical Uses See Also

BoilerDC Downcomer in drum/downcomer/waterwall loop NetSolve/Flow

BoilerSepar Drum in drum/downcomer/waterwall loop NetSolve/Flashtank

BoilerSurf Waterwall in drum/downcomer/waterwall loop OnceThroughBoiler/HxO

• Any number of boiler circulation pumps

• Any number of economizer recirc valves

• Any number of drain valves

DrumBoiler Version 5.3.2, December 2016 6

The heat release from evaporation is given by

Qdcev = (Hdc – Hlsat2) * Rdc2p * Ldc * (1 – Adc) * Kdca / Kdcevt

Hdc – Downcomer enthalpy (BTU/lb)

Hlsat2 – Saturated liquid enthalpy at downcomer two phase boundary (BTU/lb)

Rdc2p – Density at downcomer two phase boundary (lb/ft3)

Ldc – Downcomer two phase length (ft)

Adc – Downcomer two phase void fraction

Kdca – Downcomer cross-sectional area (ft2)

Kdcevt – Downcomer two phase length time constant (sec)

DrumBoiler Version 5.3.2, December 2016 7

The steam formation rate is given by

Wdcev = Qdcev * (Hvsati – Hlsati)

Hvsati – Saturated vapor enthalpy at downcomer inlet (BTU/lb)

Hlsati – Saturated liquid enthalpy at downcomer inlet (BTU/lb)

Fdcvx = Kdca * Rvsati * Vbub * Adc / (1 – Adc) * Kdcvbub

Rvsati – Saturated vapor density at downcomer inlet (lb/ft3)

Vbub – BoilerSepar pool bubble velocity (ft/sec)

Kdcvbub – Downcomer bubble rise velocity scalar

The rate of change of steam in the downcomer is given by

dMdcps = Wdcev - Fdcvx

The change in downcomer void fraction is given by

dAdc = dMdcps / Kdca / Rvsati / Ldc

Boiler Circulation Pumps

DrumBoiler Version 5.3.2, December 2016 8

The pressure increase across each pump is given by

K0bcp1 – zeroth order pump curve coefficient

K0bcp2 – first order pump curve coefficient

K0bcp3 – second order pump curve coefficient

R – liquid density in downcomer (lb/ft3)

w – flow rate thru pump (lb/sec)

Boiler Circ Pumps configuration

• Specify the number of boiler circ pumps using NBCP.

• Specify the pump curve coefficients using K0bcp1, K0bcp2, K0bcp3.

• Specify the boiler circ pump elevation using KBCPEL.

Boiler Circulation Pump Surge

DrumBoiler Version 5.3.2, December 2016 9

irc Pumps Surge configuration

• Specify the maximum surge flow of each pump using KSurgeMx[i].

These values must be configured during testing.

Boiler Circulation Pump Burp

DrumBoiler Version 5.3.2, December 2016 10

Recircs configured with a Valve object

• The FECRV[i] (current mass flow) is calculated by the algorithm.

DrumBoiler Version 5.3.2, December 2016 11

Recircs configured with a Flow Coefficient

• The FECRV[i] (current mass flow) is calculated by the algorithm.

Preserving Recirculation Mass Flow

DrumBoiler Version 5.3.2, December 2016 12

Drains configured with a Valve object

• The FDRAIN[i] (current mass flow) is calculated by the algorithm.