HRSG Users Group 26-04-14 Inspecting HRSG During Planned Outages

Inspecting HRSG During Planned Outages
2014 HRSG User’s Group Conference

February 26 – Las Vegas
• Joe Frey
• Claudio Allevato
• Mauro Araujo
• Arilson Silva
In development
2
In development
3
INTRODUCTION
The objective is to present:
• The difficulty related with inspection on HRSG

• Advanced NDT used on HRSG inspection
• Mechanical Integrity Program
• Monitoring HRSG in operation/outage
4
Mechanical Integrity Program
Large boilers HRSG large boilers Compact boilers
Fire tubular boilers

Medium size boilers Recovery boilers
5
HRSGs are NOT Designed and
Built With Inspection In Mind
Difficult access to inspection
6
Typical head counts
Typical Tubes Tube Header

Headers
HRSG (m) Welds Welds
How many
51,100 13,800 246 1,230
are there?
How many
are 540 3,000 143 738
accessible?
7
• Damage mechanisms don’t have an
accent………….I do!
8
INSPECTION ACCESS – TUBES
60000
50000
QUANTITY
40000
30000
20000
10000
0
HRSG GDE
LARGE MED
TOTAL 51100 25430 5500
INSPECTABLE 540 15980 4950
9
HRSG BOILERS
limited access to fin tubes inspection
10
HRSG BOILERS
limited access to fin tubes inspection
11
Comparing with a large boiler
12
ACCESS TO TUBE WELD INSPECTION
15000
QUANTITY 10000
5000
0
HRSG GDE
LARGE MED
TOTAL 13800 5000 1800
13
HRSG BOILERS – Access to tube weld inspection
ABLE TO INSPECT 3000 WELDS (22%)
14
ABLE TO INSPECT 4000 WELDS (80%)
15
ACCESS TO HEADERS INSPECTION
300
Headers
250
200
QUANTITY
150
100
50
0
HRSG GDE
LARGE MED
TOTAL 246 19 6
16
HRSG BOILERS – Access to headers inspection
ABLE TO INSPECT 100 to 200 HEADERS (50%)
17
ABLE TO INSPECT 19 HEADERS (100%)
18
ACCESS TO INSPECT HEADER WELDS
WELDS OF HEADERS
1400
1200
1000
800
QUANTITY
600
400
200
0
HRSG GDE MED
TOTAL 1230 95 30
19
HRSG BOILERS
access to header weld inspection
ABLE TO INSPECT 738 HEADER WELDS (60%)
20
ABLE TO INSPECT 85 HEADER WELDS (85%)
21
HRSG - Mechanisms
• Corrosion Fatigue
• Corrosion under insulation
• Metallurgical Damages
• Thermal Fatigue
• Creep Fatigue
• Flow-Inducted Vibration Fatigue
• Waterside & Steamside Oxide Growth &
Deposits
• FAC
Source: EPRI
22
Mechanisms (cont’d)
• Acid Phosphate Corrosion
• Caustic Gouging
• Hydrogen Damage
• Pitting
• Gas-Side Corrosion
• Acid Dew Point Corrosion
• Stress Corrosion Cracking
• Short Term Overheating
• Long Term Overheating
• Thermal Quenching-Induced Fracture
Source: EPRI
23
Map/guide of susceptible mechanisms
8 8
1 Manufacture /
welding 4
1 1
SCC / ACID
2
CORROSION - EXT
SCC-INT
3
CORROSION FATIGUE
6 6 6
FAC – Flux accelerated 1 1
4
corrosion 5 5
5 Abrasion 3 3
Thermal Fatigue 4 4
6 7
– Stress Rupture 2
7 Creep / Creep Fatigue
8 Corrosion under
insulation
24
Welding defects - manufacture
25
Dew point corrosion / SCC
26
Internal SCC – socket weld drain line
27
Corrosion under deposit
Hydrogen damage phosphate
28
FAC – Flow Accelerated Corrosion
Source: HRSG inspection Planning Guide
29
Abrasion – in support area
30
Rupture of bolts and bowing of tubes
31
Low Cycle Fatigue
Source: HRSG inspection Planning Guide
32
Low Cycle Fatigue
HL-1A
33
Corrosion Under Insulation
34
Cracks – Thermal Fatigue
35
Mechanisms vs NDE methods
8 8
1 Manufacture /
welding 4
1 1
SCC / ACID
2
CORROSION - EXT
SCC-INT
3
CORROSION FATIGUE
6 6 6
FAC – Flux accelerated 1 1
4
corrosion 5 5
5 Abrasion 3 3
Thermal Fatigue 4 4
6 7
– Stress Rupture 2
7 Creep / Creep Fatigue
8 Corrosion under
insulation
36
Inspection plan - HRSG
Mechanism - Manufacture / Welding 1 + Thermal Fatigue 6
Damage – Incomplete fusion + cracks
Susceptible areas: Tube welds & headers
Advanced NDTs – Eddy Current / Phased Array
37
Mechanism – Thermal Fatigue 6
Damage – cracks
Susceptible areas: Tube welds & headers
Advanced NDTs – Eddy Current / Phased Array
5,7mm
Eddy Current
Phased Array
38
Mechanism: Thermal Fatigue6
Damage: Cracks
Susceptible areas: Drum & piping
Advanced NDT – Acoustic Emission
39
Mechanism: Thermal Fatigue 6
Damage: Cracks
Susceptible areas: Headers & piping
40
Damage: Cracks
Susceptible area: Drum
41
Damage: Cracks
Strong correlation between AE data and thermal stresses parameters (pressure, temperature)
RESFRIAMENTO SH2
450,0
400,0
350,0
300,0
250,0
200,0
150,0
100,0
50,0
0,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
0
0
0
0
0,
3,
6,
9,
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
63
66
69
72
HORAS
1300_TI-031A 1300_TI-031B 1300_TI-031C 1300_TI-031D 1300_TI-031E 1300_TI-031F

1300_TI-031G DT max. VAPOR t/h T.AGUA ALIM.
42
Damage: Cracks
Eddy Current, Phased Array
43
Mechanism - FAC 4
Damage – Thinning
Susceptible areas: where the temperature of water from 175º F to 445º F,
there is turbulence and change of flow direction
NDTs – A/B/C-scan, thickness measurement (small diameter transducer)
44
Mechanism: FAC 4
Damage: Thinning
Susceptible area: Tubes, Headers & Nozzles
Advanced NDT – A/B/C/D-Scan (UT)
A A
C-SCAN View
D-SCAN View Section A-A
45
4
FAC – Tubes , Headers & Nozzles
Advanced NDT – A/B/C/D-Scan
DER-2A1
46
Superheated Steam Piping
Mechanism – Fatigue / Creep Fatigue 7
Damage – Cracks
Susceptible areas: Headers, Superheated Steam Piping
Advanced NDTs – Acoustic Emission, Eddy Current, PAUT, ToFD, Metallurgical
Replication; Hardness
47
Fatigue / Creep Fatigue 7
Advanced NDT – Acoustic Emission - cracked header
Termocouple installed in the Header. Found a variation aproximatly 60º F .
Constant No AE
AE activity during the temperature
temperature variations activity
48
Non destructive Metallurgical Evaluation
Example of Boat Sample. Source: internet
Boat Sample
49
Fatigue / Creep Fatigue 7
Advanced NDT – Phased Array & Eddy Current
Eddy Current
Phased Array
CRACKS
50
Superheated and Reheater
Mechanism – Creep 7
Damage – Microvoids, Microcracks, cracks, Metallurgical damage
Susceptible areas: Tubes
NDTs – Metallurgical Replication; Hardness, Oxide layer (UT), thickness (UT) and
dimensional measurements
51
HISTORY OF INTERNAL OXIDE THICKNESS

OPERATION LAYER
TIME OF STRESS
TEMPERATURE
OPERATION
CREEP LIFE
52
General Inspection plan - HRSG
• A/B/C-Scan
• Endoscopy
• Replications / Hardness / Diameter and oxide layer mesurement
• PAUT / ToFD
• Eddy-current
• Non destructive Metallurgical examination
• Acoustic Emission
53
Modeling the mechanic behavior

of components in real conditions
Basis
for:
• Interpretation of results of AE monitoring

• Planning of NDTs when boiler is out of service.
Local stress due to top to bottom temperature

difference caused by improper spray control
Source: Alston
54
Future Plan of Control - HRSG
Deterioration
Mechanism, Analysis
Project
damage, Mechanical Diagnostic
Data
variable of Corrosion
control
Instrumentation
Project of • Existing (T, P, PH)
monitoring • Additional (AE, Stress,
in service T…)
NDT
Plan of • Where ?
Inspection • How ?
• Mechanical Integrity
Analysis of
• Root cause analysis of
results
damages and failures
Repair project
Design
and quality
Improvement
control
55
By combining selected NDT methods (FMR, AUT,
AET, EC, etc.) to areas susceptible to certain
damage mechanisms, with stress analysis,
operational data collection and on-line monitoring,
future failures can be pro-actively predicted,
leading to a reduction of efforts during outages.
56
Thank You. Questions?
57

HRSG Users Group 26-04-14 Inspecting HRSG During Planned Outages

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HRSG Users Group 26-04-14 Inspecting HRSG During Planned Outages

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Droits d'auteur :

Formats disponibles

Inspecting HRSG During Planned Outages

2014 HRSG User’s Group Conference

The objective is to present:

• The difficulty related with inspection on HRSG

Large boilers HRSG large boilers Compact boilers

Fire tubular boilers

Difficult access to inspection

Typical Tubes Tube Header

ABLE TO INSPECT 4000 WELDS (80%)

ABLE TO INSPECT 19 HEADERS (100%)

Hydrogen damage phosphate

Source: HRSG inspection Planning Guide

Source: HRSG inspection Planning Guide

1300_TI-031A 1300_TI-031B 1300_TI-031C 1300_TI-031D 1300_TI-031E 1300_TI-031F

D-SCAN View Section A-A

Termocouple installed in the Header. Found a variation aproximatly 60º F .

Example of Boat Sample. Source: internet

HISTORY OF INTERNAL OXIDE THICKNESS

Modeling the mechanic behavior

• Interpretation of results of AE monitoring

Local stress due to top to bottom temperature

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