Boiler Process Modelling and Simulation

Steady-state and transient modelling of boilers and HRSGs, from heat balance to full plant models.

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Boiler Process Modelling and Simulation

Tetra Engineering provides a full-scope service for the modelling and operation analysis of all types of natural or forced circulation Power Boiler and HRSGs, including supercritical and once-through designs.  This can be integrated into a full plant model to incorporate the steam turbine and steam cycle balance of plant.

The level of detail can be adapted to focus on local effects (e.g. row-to-row temperature differences) and can be steady-state or time-dependent, the latter to model transients such as startups.  The state-of-the-art Power Plant Simulator and Designer™ (PPSD) software package developed by KED software is the primary tool for this work.  Frequent applications at Tetra Engineering include:

  • Calculating steam cycle efficiency (heat balance) according to ASME PTC or other codes
  • Determining natural circulation rates in support of FAC risk assessment
  • Generating metal temperature profiles for inputs to finite-element stress calculation
  • Assessing the impact of design changes or modification to original plant operating regime
Boiler Process Modelling and Simulation
Boiler Process Modelling and Simulation
Boiler Process Modelling and Simulation
Tetra Engineering logo. Orange triangular pyramid on a black background.Tetra Engineering logo. Orange triangular pyramid on a black background.

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To discuss how we might assist you to improve your plant's performance or to maintain its value over time

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Related Engineering & Analysis Services

Finite Element Analysis (FEA)

Finite Element Analysis (FEA)

Finite element analysis of HRSG components to quantify fatigue and thermal stress from cycling operation.

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Fitness for Service

Fitness for Service

Assessments of whether damaged boiler, HRSG and piping components can safely stay in service.

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Boiler Process Modelling and Simulation

Boiler Process Modelling and Simulation

Steady-state and transient modelling of boilers and HRSGs, from heat balance to full plant models.

learn more
Flow Accelerated Corrosion Assessment (FAC)

Flow Accelerated Corrosion Assessment (FAC)

Identify and prevent tube and pipe thinning caused by flow-accelerated corrosion (FAC) to avoid ruptures and leaks.

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Optimized NDE

Optimized NDE

We target NDE at the locations most likely to be damaged, with pre-outage planning, on-site supervision and post-inspection review.

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Root Cause of Failure (RCA)

Root Cause of Failure (RCA)

Knowing the fundamental causes leading to failure is essential to mitigate the risk of the failure repeating. Tetra Engineering calls on an interdisciplinary team to assess the failure (or degradation) and determine the root cause.

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Performance & Efficiency Assessments

Performance & Efficiency Assessments

Services to help you evaluate how your operating performance has changed since the plant / boiler was commissioned, or to help you check the potential performance impact of planned modifications before they are implemented.

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Life Assessments

Life Assessments

Knowing the remaining useful operating life of your boiler, HRSG and associated balance-of-plant is a key parameter for effective management of your thermal power plant.

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Recent Resources

Stay up to date and refer to our large collection of technical white papers and articles

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HRSG Preservation During Shutdowns: A Key Issue Often Neglected
News

HRSG Preservation During Shutdowns: A Key Issue Often Neglected

Idle periods are getting longer as plants move to cycling or standby, and corrosion during layup can do serious damage. Pitting can penetrate a tube wall in a few weeks. In the October 2026 issue of Modern Power Systems, Misha Gadher and James Malloy of Tetra Engineering Europe compare five preservation methods and show how one coastal combined cycle plant matched each method to each system for a six-month shutdown.

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Tetra Engineering logo. Orange triangular pyramid on a black background.Tetra Engineering logo. Orange triangular pyramid on a black background.

Contact Us

To discuss how we might assist you to improve your plant's performance or to maintain its value over time

Contact Us