HRSG Maintenance & Operating Issues

David Buzza Region 7 Engineering August 6, 2012

Lawrenceburg Primary Reheat Tube Failures

Tubes bowed at header ends

Looking Up

Lawrenceburg Primary Reheat Failures & Cracks Four HRSG Units From Feb 2009 to Aug 2011 - 9 forced repairs and 5 unforced repairs. 37 of 45 tube repairs are near header ends versus over drain lines.

Panel Top Header

Crack at toe of fillet weld (tube side)

Reducing Lawrenceburg Primary Reheat Failures

Condensate in bottom header creates preferential steam path for tubes over drains.
Tubes over drains are cooler. Tubes at ends are hotter.

Found attemperator water leaking through between starts. Corrective Action

Manually closed all attemperator water between starts. Increased manual drain to 2 inch and drained header prior to each start.

Lawrenceburg LP FW Heater / Economizer Deposits

Deposit may be corrosion and/or ammonium sulfate / bisulfate deposit. Need sample to verify.

LP Economizer Protection
Maintain FW inlet temperature 15F above flue gas dew point with FW recirculation system.

Lawrenceburg Distribution Grid Failure

Grid Start of Tube Panels Duct Burner SCR

Turbine to HRSG expansion joint

Distribution Grid
Supports HRSG Casing

Guides

Distribution Grid
54 feet

(7/8 overlap)

Top = SS Bottom = P11

Guides (1 overlap)

25 feet

Lawrenceburg Failed Distribution Grid

Failure

Gas Flow Tube Bundle downstream of Grid Distribution Grid

Turbine Exhaust Gas Velocity at Turbine Exhaust

33 m/s 83 m/s 25 m/s

Turbine Exhaust Gas Velocity at the SCR

With Distribution Grid No Distribution Grid

5 m/s

Turbine Exhaust Gas Velocity at the Duct Burners

With Distribution Grid

No Distribution Grid

6 m/s

9 m/s

Turbine Exhaust Gas Velocity at First Tube Bundle

With Distribution Grid No Distribution Grid

8 m/s

8 m/s
26 m/s 16 m/s 32 m/s

Concern Gas & acoustic baffles and/or tube ties may fail with no distribution grid because of higher gas velocity / higher tube vibration.

Eliminating Single Point Trips / Runbacks Lawrenceburg Plant DCS

Event Single Points Resolution Remove trip, already protected by GT exhaust P trip Gas Turbine high HRSG duct P trip

Gas Turbine high HP or HRH steam Add 2 XMTRs for 2/3 median runback T select for each Boiler Feed Pump trip Boiler Feed Pump trip High vibration or high bearing T Low NPSH (P&T) Remove trip, allow operator to decide Add 2 XMTRs for each for 2/3 median select Add 2 XMTRs for 2/3 median select Add 2 XMTRs for 2/3 median select for each

Condensate Low condenser level Pump trip Duct Burner High HP 2ndary P trip High HP 1st or 2nd T High RH 1st or 2nd T

Waterford HP Pipe Support Cracking

Pipe Movement

Crack Stanchion

Crack

Waterford HP Pipe Support Repair

Shortened stanchion from 27 to 9 long to reduce moment arm Added plate to bottom of stanchion to improve sliding

Waterford HRSG Drain Line Pipe Buckling and Support Failures

Bent Support

Buckled Drain Line

Waterford HRSG Drain Line Repair

Re-ran the pipe with expansion loops

Lawrenceburg Boiler Feed Pump Piping Support

Existing Support

Existing Support

New Support

Existing Support

To BFP Suction

Lawrenceburg Boiler Feedwater Pump Vibration

Pump Drive End & Non Drive End Vibration, mils Before
9

After BFP 1

0 9

BFP 2

0 9

BFP 3

0 9

BFP 4

Time

Improving Reliability of Gas Regulating Station for Duct Burners

Lawrenceburg Plant

Need PM that includes replacement of regulator soft goods. Verify that all regulator valves have proper set points. Add vortex heater to prevent freeze up of regulator orifice & distillate drop out in pilot gas.