HRSG-09 Wholistic Approach To HRSG Inspections - Turner

A Wholistic Approach to HRSG
Inspections
Charles Turner, P.Eng.

Charles G. Turner & Associates Ltd.
Consulting Engineers
Presented at the
2014 Canadian HRSG Forum
October 21, 2014

Charles G. Turner and Associates Ltd.
(CGTA)
Consulting Engineers specializing in Power

& Utilities
Founded in 1973
Located in Toronto, Ontario, Canada

CGTA Areas of Expertise
Simple Cycle and Combined Cycle Power Plants
Thermal Power Stations (Coal, Gas & Oil Fired)
Cogeneration (Steam Turbines, Gas Turbines &
Reciprocating Engines)
Central Heating Plants (Steam Boilers, Thermal
Fluid Heaters & Vaporizers, Glycol & Hot Water,
Plant Auxiliaries, buried steam & HW distribution
piping)
Central Cooling Plants (Chilled Water,
Refrigerant, Steam Absorption & Ammonia, buried
chilled water distribution piping)

CGTA Areas of Expertise
Continued
Burners & Combustion (Natural Gas, Fuel Oil,
Liquid and Gaseous Process Fuels, Biomass)
Water Treatment Systems
Compressed Gas Plants (Air, Digester Gas, Landfill
Gas and Carbon Dioxide)
Industrial Plant Processes
Industrial HVAC
Cooling Tower Systems
Instrumentation & Controls (PLC & DCS)
Electrical Generation (High and Low Voltage)
Putting Wholistic into
HRSG Inspections
Wholistic refers to the approach and execution of
the HRSG inspection, where the HRSG is inspected
from an asset integrity and management approach.
The approach integrates the HRSG inspection and

boundary limits into the Companys long term
maintenance plan that includes;
Integrity Plans
SAMPs
Long Term Maintenance Plan

Aligning Inspection Deliverables within
the Asset Management Plans
What is a Corporate Asset Management Plan?
Defines the organizational goals and objectives of the
plant components.
Defines performance targets.
Provides future demand forecasts.
Specifies regulatory requirements.
Identifies site specific maintenance intervals, capital and
operating improvement projects.
Records equipment condition.
Provides a summary location for the performance
history and operating strategy to maintain performance
requirements.

HRSG Integrity Plans
HRSG Integrity Plans are developed to support
the Asset Management Plans:
Defines the life cycle wholistic view of the specific
equipment.
Incorporates Operations and Maintenance strategies.
Develops Risk Assessment including analysis and
consequences.
Defines Provincial and State compliance requirements.
Assurance of Insurance compliance requirements.
Provides a basis for the lessons learned.

Critical Pre-Inspection
Key Parameters
HRSG Superstructure Design
Bottom supported components
Top hung from casing superstructure
Waste Heat Source:

Gas Turbine - Size/Make/Model
Duct Firing Location and rating
Operating Parameters
Number of Pressure Levels
Pressure/Temperature
Operating Hours
Number of Cold Iron Starts, Cold/Warm/Hot Starts, Forced
Cooling Events, and EOHs.
Critical Pre-Inspection
Key Parameters Continued
High Temperature Materials

P91/T23
Hardened Low Temperature Regions for FAC
In-Cycle water treatment program

HP & IP Phosphate / LP SALP or FFLP?
Once Through requirements.
Cascading Blowdown.

Typical F Technology Triple
Pressure HRSG

Once Through Steam Generator

Enhanced Oil Recovery Once Through
Wet Steam Generator

External Casing Inspection

Casing Expansion Joint Limited
Flexibility

Casing Hot Spots

External Casing Liquid Refractory
Injection Locations

Thermography Analysis
Transition Duct Liner
Issue Casing Hotspot

Thermography Analysis
Sidewall Bellows Failure Door Seal Leak

External Piping Supports

HEP BEP Supports

HEP BEP Supports

HRSG Superstructure Supports

Duct Burner Blowers

Duct Burner Manifolds

Preheater Recirculation Pump

Pump Inlet Expansion Joint

Preheater Expansion Joint
Misalignment

Preheater Expansion Joint Failure

Lower Vestibules

Chemical Clean Connections

Gasket Leaks

Small Bore Drain Line Pinhole
Leaks

OTSG Side Vestibules

OTSG Sidewall Bundle Restraint

Lower Vestibule and Outlet
Header

Swaged Fitting Tube Plugs

EOR OTSG Vestibule

EOR OTSG Return Bend
Inspection

Drain Lines Inspection

Corrosion Under Insulation

Internally Insulated Gas Tight
Expansion Joint

Removed Drain Line

Corroded Drain Line

Distorted Vestibule Upper
Tubesheet Limit Guide

Tubesheet to Fin Tube Lockup

Upper Vestibule Vent Line
Distortion

Tube Support Module Splay

HRSG Inlet Transition Section

OTSG Steam Outlet Header

Tubesheet Distortion

Tubesheet Witness Marks

Fin Tube to Tubesheet
Ratcheting Effect

Tube Collar Installation

Tube Collar Migration

Tube to Tubesheet Ratcheting
and Collar Movement

OTSG End Gas Seal Plates

OTSG Tube Return Bends

Return Bend Indentation

OTSG Return Bend Indentation

Exhaust Gas Distributor

Exhaust Gas Perforated Plate

Duct Burners

Vertical Duct Burner

Horizontal Configuration
Duct Burner

Duct Burner
Fixed Igniter End

Bat Wing Bluff Body
Configurations

Duct Burner
Floating Element End

Duct Burner Element
Wall Liner Distortion

Duct Burner Pinning

Duct Burner
Cavity Liner Distortion

Duct Burner Cavity
Wall Liner Distortion

Duct Burner Cavity
Liner Replacement

Inlet Duct Insulation Block

Superheater & Reheater Modules

HRSG Bottom Supported
Superheater

Sliding Floor Seal Distortion

Floor Seal Plate Failure

Tube Distortion and Migration

Plug Weld Failures

Scallop Bar Failure & Distortion

Scallop Bar Tube Impingement

Robust Scallop Bar Design

OTSG HP Superheater Tubes

Swollen HP SH Tube

OTSG Tube Rupture

OTSG Circuit Plugging

OTSG SH Ruptured Tube

Freeze Damage

Superheater & Reheater Upper
Vestibule Floor Seal Plates

Upper Header Supports

Top Hung Module
Saddle Supports

Support Saddle Crack

Tube to Header Inspections

Superheater Toe Welds

Lower HP SH & RH Links

Lower SH Drains & Penetrations

Evaporator & Feedwater Modules

Exfoliated Fin Deposits

Feedwater Heater
Vents & Supports

Top Support Systems

Evaporator Support Fixtures

Exhaust Duct and Stack

Heavy Exfoliation and
Sulphur Deposition

Preheater Tube
UT Wall Thickness Monitoring

Exhaust Transition Expansion Joint

Exhaust Duct/Stack Inlet
Expansion Joint

Sulphur Deposits

Sulphur On Stack Floor

Rectangular Duct Damper Blades

Typical Circular Stack
Butterfly Damper

Closed Butterfly Dampers

Stack Silencers

Drum Inspections

Primary Separators, Secondary
Mesh Demisters and Chevrons

Drum Wall Wash Effect

HP Drum Primary Separators and
Demister/Chevron Assemblies

Underside of HP Primary
Separator

HP Drum Floor Deposits

Chevron Separator Failure

Demister Pad Blow Out

Demister Pad/Chevron Assembly
at Saturated Steam Lead

Steam Water Level Line

HP Downcomer Passivation

IP Drum

IP Demister Pads

LP Drum

LP Drum Water Line

LP Feedwater and Evaporator
Riser Distributors

LP Drum Deposits

LP Demister Pads

Door Castellation Seals

Dont Forget the Blowdown Tank

And Remember the Interstage
Attemperators

Tig Weld Cracks

And Borescope Liner Upstream &
Downstream

Now On To Pigging

Cleaning Pig & Before/After
Foam Dewatering Pigs

Feedwater Inlet & Steam Outlet
Borescopes

Pig Launcher

Pig Launchers/Receivers

Borescope Inspection

Pigged Steam Lines

Pigged Gasket Results

Incorporating the Inspection Results into
the LONG TERM MAINTENANCE PLAN
The Long Term Maintenance Plan (LTMP) will define the scope,
frequency and estimated cost of equipment maintenance required to
attain expected plant availability.
The LTMP will be built based on the outputs of the equipment Integrity
Plans and the System Asset Management Plans (SAMP).
Integrity Plans SAMPs LTMP
Objective: Develop Objective: Develop specific Objective: Develop wholistic

equipment specific plans plans utilizing operating plant view on scope, frequency
defining maintenance intervals, assumptions and performance and cost of outages over 5 and
related projects and applicable history 20 year horizons
operating procedures.

LTMP & Business Plan
LTMP Linkage with the Annual Business Plan
The LTMP will include the following;

Discussion on Integrity Plans and SAMP content as it relates
to the long term maintenance requirements.
Short term view showing major outage work scopes, durations
and cost estimates.
Long term view showing major outage work scopes, durations
and cost estimates.
With the combination of Integrity Plans and SAMPs in the LTMP,
which should be reviewed and updated on an annual basis, the
annual Business Plan will contain an accurate maintenance scope,
duration and cost estimates for the coming year.

Incorporating the Inspection
Findings into a Risk Registry
The Risk Registry is a tool used to document risks known
to Management and associated mitigation activities.
As a group the management team distributes risks
appropriately to team members, who become the risk
manager.
The Risk Manager is responsible for documenting current
mitigation activities or developing strategies for further
mitigation when appropriate.

Calculate Risk Value
A Risk Value is calculated using the probability, frequency
and impact values.

A Wholistic Approach to HRSG
Inspections
Concluding remarks:
Know what you are up against.
Begin the inspection with the end in
mind.
Understand the deliverables of the
inspection.
Hope for the best, prepare for the
worst.

Thank you for your
time & interest.
Questions?

HRSG-09 Wholistic Approach To HRSG Inspections - Turner

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A Wholistic Approach to HRSG

Charles Turner, P.Eng.

Charles G. Turner & Associates Ltd.

Consulting Engineers specializing in Power

Located in Toronto, Ontario, Canada

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

The approach integrates the HRSG inspection and

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Waste Heat Source:

High Temperature Materials

Hardened Low Temperature Regions for FAC

In-Cycle water treatment program

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.

Charles G. Turner & Associates Ltd.