HRSGInspectionTasks

PresentedBy:
BryanF.Craig,P.E
HRSTInc.

8/10/2009 Columbus, OH AEP / BRO Forum 1

HRSGInspection
Goals:
1. Documentconditionofequipment
2. Identifyitemsthatneedimmediate
maintenance
3. Identifyitemsthatneedbudgetingand
planningformaintenancenextyear
yp y, g
4. Identifyproblemsearly,allowingtimefor
scrutinyandanalysis
5. Duediligence..showstakeholdersyouhave
proactiveapproach.
8/10/2009 Columbus, OH AEP / BRO Forum 2

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 HRSGInspection
KeyElements
1. Dedicatedinspectors
Good inspections take days not hours!
Goodinspectionstakedaysnothours!
2. Recordingobservations(facts)
Photos,measurements,notes
3. Organizefactslogically
Everyfactshouldbeaccuratelylinkedtoaspecificlocation.
4. Measurementsatcriticalareas
Thickness(UT),Gapdistance,cracklength
5. Threelocationtypes
GasPath
Steam/WaterSide
Exterior
8/10/2009 Columbus, OH AEP / BRO Forum 3

HRSGInspection
GasSideInspectionAreas
AccessLanes(inletduct,firingduct,SCR,
l
lanesbetweentubebundles,stack)
b t t b b dl t k)
Crawlspacesunderandabovetube
headers
Importanttodocumentlocationsclearlyfor
future reference
futurereference
Besttoprepareinadvance,ratherthan
identifyproblemlocationsonthefly

8/10/2009 Columbus, OH AEP / BRO Forum 4

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8/10/2009 Columbus, OH AEP / BRO Forum 5

GasSideTasks
InletDuctItems:*
1 LinerSystem
1. Liner System
Looseplates,spinningwashers,exposedinsulation,
failedstuds.
2. Flowdistributionplatesorvanes
3. Tubes&Fins
corrosion warping vibration wear
corrosion,warping,vibrationwear
4. Baffles&TubeTies
vibrationdamage,wear,expansioninterferences,weld
cracks.
8/10/2009 Columbus, OH AEP / BRO Forum 6

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 InletDuctLiner
Loose&brokencomponents

8/10/2009 Columbus, OH AEP / BRO Forum 7

InletDuctLiner
SpinningWashers

8/10/2009 Columbus, OH AEP / BRO Forum 8

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 InletDuctLiner
LinerGaps,ExposedInsulation

8/10/2009 Columbus, OH AEP / BRO Forum 9

FlowDistributionGrid

8/10/2009 Columbus, OH AEP / BRO Forum 10

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 TubeTies

Tube & fin wear

at tube tie

8/10/2009 Columbus, OH AEP / BRO Forum 11

FailedTubeTies

8/10/2009 Columbus, OH AEP / BRO Forum 12

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 GasSideTasks
FiringDuctChecklist
1. LinerSystem(sameasinletduct,pluslookforoxidized
components)
p )
2. DuctBurner:
Saginelementsorbaffles
Nozzleplugging
Cokebuildup
Burnerwingcondition
3. Tubes&Fins(sameasinletduct,plus)
Evidence of flame impingement or local hotspots
Evidenceofflameimpingementorlocalhotspots
4. Baffles&Supports
5. Locationoffiringductthermocouples

8/10/2009 Columbus, OH AEP / BRO Forum 13

Reheater upstream of duct burner

8/10/2009 Columbus, OH AEP / BRO Forum 14

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 BurnerBaffleFailures
Coen baffle weld seam
cracks & failures

Coen fix for baffle weld

seam cracks & failures.
May not be enough, some
cracking still being found.
8/10/2009 Columbus, OH AEP / BRO Forum 15

8/10/2009 Columbus, OH AEP / BRO Forum 16

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 CarbonBuildup

Carbon inside gas pipe.

Build up has fractured the
gas pipe.

Coking: Usually due to olefins in refinery gas. Sometimes coking occurs

with natural gas due to poor air/fuel mixing at burner.

8/10/2009 Columbus, OH AEP / BRO Forum 17

OxidizedLinerComponents

8/10/2009 Columbus, OH AEP / BRO Forum 18

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 LocalBurnerHotspots

8/10/2009 Columbus, OH AEP / BRO Forum 19

GasSideTasks
TubeBundleAccessLaneChecklist:
1. LinerSystem(samechecksasinlet&firing
y ( g
ducts,problemslessprevalent)
2. Tubes&Fins:corrosion,warping
3. Baffles&Supports(sameasprevious)
4. Catalyst
Foulingg
Gasbypassaroundperimeter
Packingbetweenblocks

8/10/2009 Columbus, OH AEP / BRO Forum 20

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 Tube&FinFouling

8/10/2009 Columbus, OH AEP / BRO Forum 21

Tubes&Fins
TubeBuckling Superheaters&Economizers

8/10/2009 Columbus, OH AEP / BRO Forum 22

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 Tubes&Fins
Cracking HPSHTube

8/10/2009 Columbus, OH AEP / BRO Forum 23

GasBaffles
Exhaust flow into page

Sidewall Baffles

Upper Header
Center
(Laning)
Baffles Tubes

Lower Header
Header
(Bulkhead)
Baffles

8/10/2009 Columbus, OH AEP / BRO Forum 24

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 BaffleFailures

8/10/2009 Columbus, OH AEP / BRO Forum 25

BaffleGapsDecreasePerformance

8/10/2009 Columbus, OH AEP / BRO Forum 26

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 CatalystFouling

CatalystGasBypass

8/10/2009 Columbus, OH AEP / BRO Forum 28

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 GasSideTasks
CrawlSpaceChecklist:
1. Waterfromtubeleaks?
2. Floordebris
3. Linercondition
4. Linerfituparoundpipingandhanger
penetrations
5. Baffles
6 Bentpiping
6. Bent piping
7. Headercorrosion
8. Tube/headerjointcondition(ifvisible)

8/10/2009 Columbus, OH AEP / BRO Forum 29

Spray pattern is a leak indication

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 Fin scale debris on
crawlspace floor

Oxidized carbon steel debris

on crawlspace floor

16
Accelerated corrosion Roof debris blocks drainage
near penetrations, holes, trapping rainwater.
probably caused by rain
water leaking past
penetration seal.
8/10/2009 Columbus, OH AEP / BRO Forum 34

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 BulkheadGasBypass

Hot
Exh

8/10/2009 Columbus, OH AEP / BRO Forum 35

Gap between
baffle and floor is
too large, allows
gas bypass,
decreasing
performance.

8/10/2009 Columbus, OH AEP / BRO Forum 36

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 BentDrainsIndicateStress

8/10/2009 Columbus, OH AEP / BRO Forum 37

ExteriorTasks

ExteriorInspectionChecklist
Exterior Inspection Checklist
1. Casinghotspots,cracks
2. Pipingpenetrationseals
3. Accessdoorcondition
4 Foundations
4.

8/10/2009 Columbus, OH AEP / BRO Forum 38

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 Casing
AccessDoors HotSpot

8/10/2009 Columbus, OH AEP / BRO Forum 39

PenetrationSeals

Bellows cracks can be difficult to

8/10/2009 Columbus, OH
see. Tight cracks, bellows are
compressed when off line. Look for
hot spots, and nearby insulation
fur.
AEP / BRO Forum 40

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 These bellow cracks were easy to
see!
However, it took some extra effort to
climb up on the roof casing to
inspect.
8/10/2009 Columbus, OH AEP / BRO Forum 41

HRST Upgraded Pipe Penetration Seal

PROBLEM:

T
Tears in
i Fabric
F bi

Cracks in Bellows

Delay box

SOLUTION:

HRST Pipe
Penetration Seals

8/10/2009 Columbus, OH AEP / BRO Forum 42

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 Casing Stress & Cracks

Expansion

Stress Points (Typ)

8/10/2009 Columbus, OH AEP / BRO Forum 43

Casing Stress & Cracks

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Casing Crack

Hotspots

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 HRSGInspection
Water/SteamSideTasks

SteamDrumsaretheonlynonintrusiveaccess
y
tothewater/steamsideinamodernHRSG.

Drumsareoftenalsoinspectedbythewater
chemistrydeptandinsuranceinspector.

8/10/2009 Columbus, OH AEP / BRO Forum 47

Water/SteamSideInspectionTasks
SteamDrumChecklist
1. Drumsurfacecondition
2. Signsofdistressonsteamseparation
equipment&bellypan
3. Thicknessofbellyplatesandsteam
separators
4. MechanicalIntegrity
g y
5. Approximatewaterlinevs.drawing
6. Debris

8/10/2009 Columbus, OH AEP / BRO Forum 48

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 DrumSurfaceCondition
1. Drumsurfacedetails(color,condition,pits)
Color
Redisgoodinanoxidizingenvironment
Redisbadinareducingenvironment
Condition
Keeptrackofsurfacedefectsfrommanufacture
Trackwhethersmoothness(roughness)ischanging
Pits
Pits
Doyouhavethem?
Whatdotheylooklikeunderneath?

8/10/2009 Columbus, OH AEP / BRO Forum 49

OxygenAttackinSteamDrum
Offline

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 HPDrumCondition

Surface defects in an HP drum from rolling steel

8/10/2009 Columbus, OH
NOT a significant issue
AEP / BRO Forum 51

SignsofDistress
2. Signsofdistressonsteamseparation
equipment & belly pan
equipment&bellypan
Cracksinthebellypan
Cracksinthefinalseparatorcorners
Weldseamsintheshellandshelltohead
Downcomerindications

8/10/2009 Columbus, OH AEP / BRO Forum 52

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 SignsofDistress
Cracks?

Baffle Cracks?

8/10/2009 Columbus, OH AEP / BRO Forum 53

HP BellyPanCracks
(orbaffleplate)

8/10/2009 Columbus, OH AEP / BRO Forum 54

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 Downcomer Indications

8/10/2009 Columbus, OH AEP / BRO Forum 55

ThicknessofBellyPans
andSteamSeparationEquipment
3. UTtest
F/W,Deltak,Vogt,NEM,Aalborg,Alstom,etc
BellyPans
Cyclones(F/W=horizontal,others=vertical)
N/EandCerrey
BellyPans(nocyclones)

8/10/2009 Columbus, OH AEP / BRO Forum 56

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 UltrasonicThicknessMeasurements
Thicknessmeasurementsareausefultoolto
documentconditionofdruminternals,tubesand
,
piping.
Bespecificaboutlocations&documentation
Mostmeasurementsaresimplethicknessfor
generaldocumentationortotrackFlow
AcceleratedCorrosion
MoresophisticatedUTusedforcrackdetection:
h d df kd
shearwave,phasedarray

8/10/2009 Columbus, OH AEP / BRO Forum 57

8/10/2009 Columbus, OH AEP / BRO Forum 58

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 Cycloneswornthrough
fromFAC

8/10/2009 Columbus, OH AEP / BRO Forum 59

BellyPanThinning
Check here!
UTinLP&IP

8/10/2009 Columbus, OH AEP / BRO Forum 60

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 LPBellyPanHole(FAC)

8/10/2009 Columbus, OH AEP / BRO Forum 61

MechanicalIntegrity
4. IntegrityofInternals
i f l
Piping
BrokenUBolts
Missingnuts
PluggedChemFeedLines
Separators
Failure
Plugging
Missinghardware

8/10/2009 Columbus, OH AEP / BRO Forum 62

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 HP FallenChemFeedLine

U bolt broke off

8/10/2009 Columbus, OH AEP / BRO Forum 63

HPDrum ChemFeedLine

8/10/2009 Columbus, OH AEP / BRO Forum 64

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 HPDrum brokencycloneattachment

8/10/2009 Columbus, OH AEP / BRO Forum 65

Deltak PerforatedPlateAbove
MeshSeparator

8/10/2009 Columbus, OH AEP / BRO Forum 66

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 Deltak MeshSeparatorFailure

8/10/2009 Columbus, OH AEP / BRO Forum 67

ApproximateWaterLine
vs.Drawing
5. WaterLineReadings
i di
Thewaterlineisoftenfalselyreadinglowdueto
proximityofthedowncomerorpumpsuctiontothe
leveltransmitters.Thesuctioneffectofthoselarge
linespullsonthelevelsensinglines.
Pluggingofthelinesisproblematiciftheyare
positionedoffthebottomoftheshell.
Thenumberonecauseoffaultylevelindicationor
controliscalibrationorcompensation

8/10/2009 Columbus, OH AEP / BRO Forum 68

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 LP waterlevel

8/10/2009 Columbus, OH AEP / BRO Forum 69

LP leveltransmitterproximity
topumpsuction

8/10/2009 Columbus, OH AEP / BRO Forum 70

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 Debrisinleveltap

Lower level tap magnetic debris

8/10/2009 Columbus, OH AEP / BRO Forum 71

DebrisinDrums
6 Debris
6. bi
Amount
Color
Magnetitevs.Hematite?
Flakesvs.Powder?

8/10/2009 Columbus, OH AEP / BRO Forum 72

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 Debrisindrum

8/10/2009 Columbus, OH AEP / BRO Forum 73

Summary
GasSide
Access Lanes (inlet duct, firing duct, SCR, between tube
AccessLanes(inletduct,firingduct,SCR,betweentube
bundles,stack)
Crawlspacesunderandabovetubeheaders
Exterior
Casinghotspots,cracks
Pipingpenetrationseals
Accessdoorcondition
Foundations
Steam/WaterSide
SteamDrumsaretheonlynonintrusiveaccesstothe
water/steamsideinmostHRSGs

8/10/2009 Columbus, OH AEP / BRO Forum 74

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 HRSGInspection
FurtherWork
OnlineorHotInspection
HRSGinspectionwhileunitisoperating
Idealforfindinghotspots,casingcracks,penetrationsealfailures
g p , g ,p
Cancheckhotpositionofspringhangers
ExtendedScopeofflineinspection
Dependingontheage,quantity&severityofcyclesandhistoryofissues,
moreintrusiveinspectiontechniquesmaybebesttoquantifycondition.
Commontechniques:
1. UTtubesandpipingbeyondspotchecks(AScan,PhasedArray,orShearWave)
2. DyePenetrant orMagneticparticletestingofsuspectareas
3. ConventionalandDigitalXRay(Radiography)
4. EddyCurrentTesting
5. PipingAssessment
6. HardnessandReplication(P91)
7. Desuperheaterremoval&inspection
8. Borescoping
9. Tubesamples

8/10/2009 Columbus, OH AEP / BRO Forum 75

AnyQuestions?

BryanF.Craig,P.E
HRSTInc.
bcraig@hrstinc.com
8138554688(office)
6127431009(cell

8/10/2009 Columbus, OH AEP / BRO Forum 76

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