Degradation modes

HRSG Operation & Inspection Seminar 2011

Schoonmaker / Decoussemaeker / Matukonis
Barcelona, 27Sep 2011

Degradation Modes
Fatigue:
- Thick walled components with high temperatures /
temperature gradients
HP drums
HPSH and RHTR outlet manifolds (fast delta t at start)

- Specific locations subject to temperature differentials

- Specific locations subject to quench during start-up, shut
down or low load operation
(desuperheater)

Creep:
- HPSH and RHTR outlet
manifolds and harps

Presentation Title - Presenters Initials - dd mmm yyyy - P 2

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

Degradation Modes
Water side corrosion
Evaporator, drums, economiser (water filled):
(or in superheater during shut down when water accumulates)
- Pitting (pits can lead to cracks): attack by oxygen
- Under deposit corrosion (deposits (e.g. evap) and contaminants)
E.g chloride from condensor (leads to hydrogen damage) or
phosphate from dosing or NaOH from dosing or resin regeneration
(leads to caustic gauging)

Flow accelerated corrosion:

- Protective magnetite layer dissolves into flowing water (single
phase) or wet steam (two phase)
Corrosion fatigue cracking at tube attachments or restraints (areas of
stress concentrations, not high enough to cause damage, but in
combination with corrosion ):
- Stress damages inner layer (magnetite), exposing it to corrosion > small corrosion filled cracks

Presentation Title - Presenters Initials - dd mmm yyyy - P 3

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

Degradation Modes
Water side corrosion

Oxygen pitting

Corrosion Fatigue

Presentation Title - Presenters Initials - dd mmm yyyy - P 4

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

Degradation Modes
Water side corrosion: FAC
Main affected locations:
Economizer: tube to header, nozzles at headers, tube bends
LP system: tube to header, elbows, downcomer at drum
Deaerators

Deaerator loss of magnetite

LP drum water separator

can: hole enlargement
(early indicator)

FAC damage at LP evaporator

tube to header connection

Economizer with magnetite loss

and material thinning

Presentation Title - Presenters Initials - dd mmm yyyy - P 5

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

Degradation Modes
Gas / atmospheric side corrosion
Gas side dew point corrosion or general stand still
corrosion
- Cooling of acidic flue gas or condensate or ambient
humidity

Pressure drop and reduced heat transfer

Presentation Title - Presenters Initials - dd mmm yyyy - P 6
ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

Degradation Modes
Overload
Freezing
Overheating:
- Long term:
Material choice over the limit, caused by design, scaling,
blockage, (at highest temp. location)
- Short term:
Start up, firing

Presentation Title - Presenters Initials - dd mmm yyyy - P 7

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

Degradation Modes
Welding problems
Dissimilar metal welds

Skill issues or lack of following of the procedure

- Combined with lack of QC

Presentation Title - Presenters Initials - dd mmm yyyy - P 8

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

www.alstom.com/power

HRSG Field Issues

Flow accelerated corrosion (FAC)
What is FAC?
- Protective magnetite layer dissolves into flowing water
(single phase) or wet steam (two phase)
- Conditions to get FAC:

Temperature between 80C and 230C

Turbulence
Carbon steel
Water chemistry (Low pH)

Typical scalloped surface

Economizer tube bends at inlet

header

Hole on top of LP evap header

(blue: thinned material)

Presentation Title - Presenters Initials - dd mmm yyyy - P 10

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

HRSG Field Issues

FAC control:
Inspection and NDE in critical areas
Water chemistry:
- Control pH (high enough) and oxygen (not zero)

Upgrade from carbon steel to material

with Cr (1 to 2%)

IP evaporator harp header

Header replacement

Presentation Title - Presenters Initials - dd mmm yyyy - P 11

ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.

HRSG Field Issues

Case Study: Replacement LP evaporator headers

Staggered design for improved accessibility for

the welding
Boroscopic Inspection Points for examination of
the weld roots
Header tube stubs are constructed from 2%
Cr, to increase the header resistance to FAC.

Use of phased array for 100% volumetric

inspection of all full penetration welds
Reduction of required outage time from 50
days to below 30 days

Improved design and reduced outage time

Presentation Title - Presenters Initials - dd mmm yyyy - P 12
ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.