HRSGInspectionTasks

PresentedBy: BryanF.Craig,P.E HRSTInc.

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AEP / BRO Forum

HRSGInspection
Goals:
1. Documentconditionofequipment 2. Identifyitemsthatneedimmediate maintenance 3. Identifyitemsthatneedbudgetingand planningformaintenancenextyear yp y, g 4. Identifyproblemsearly,allowingtimefor scrutinyandanalysis 5. Duediligence..showstakeholdersyouhave proactiveapproach.
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HRSGInspection
KeyElements 1. Dedicatedinspectors
Goodinspectionstakedaysnothours! Good inspections take days not hours! Photos,measurements,notes Everyfactshouldbeaccuratelylinkedtoaspecificlocation. Thickness(UT),Gapdistance,cracklength GasPath Steam/WaterSide Exterior
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2. Recordingobservations(facts) 3. Organizefactslogically 4. Measurementsatcriticalareas 5. Threelocationtypes

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HRSGInspection
GasSideInspectionAreas

AccessLanes(inletduct,firingduct,SCR, lanesbetweentubebundles,stack) l b t t b b dl t k) Crawlspacesunderandabovetube headers Importanttodocumentlocationsclearlyfor futurereference future reference Besttoprepareinadvance,ratherthan identifyproblemlocationsonthefly
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GasSideTasks
InletDuctItems:* 1. LinerSystem 1 Liner System
Looseplates,spinningwashers,exposedinsulation, failedstuds.

2. Flowdistributionplatesorvanes 3. Tubes&Fins
corrosion,warping,vibrationwear corrosion warping vibration wear vibrationdamage,wear,expansioninterferences,weld cracks.
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4. Baffles&TubeTies

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InletDuctLiner
Loose&brokencomponents

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InletDuctLiner
SpinningWashers

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LinerGaps,ExposedInsulation

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FlowDistributionGrid

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TubeTies

Tube & fin wear at tube tie

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FailedTubeTies

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GasSideTasks
FiringDuctChecklist 1. LinerSystem(sameasinletduct,pluslookforoxidized components) p ) 2. DuctBurner:
Saginelementsorbaffles Nozzleplugging Cokebuildup Burnerwingcondition Evidenceofflameimpingementorlocalhotspots Evidence of flame impingement or local hotspots

3. 4. 5.

Tubes&Fins(sameasinletduct,plus)

Baffles&Supports Locationoffiringductthermocouples

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Reheater upstream of duct burner

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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.
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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.
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OxidizedLinerComponents

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LocalBurnerHotspots

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

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Tube&FinFouling

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Tubes&Fins
TubeBuckling Superheaters&Economizers

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Tubes&Fins
Cracking HPSHTube

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Exhaust flow into page

GasBaffles

Sidewall Baffles Upper Header Center (Laning) Baffles

Tubes

Lower Header Header (Bulkhead) Baffles

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BaffleFailures

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BaffleGapsDecreasePerformance

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CatalystFouling

CatalystGasBypass

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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)

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Spray pattern is a leak indication

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Fin scale debris on crawlspace floor

Oxidized carbon steel debris on crawlspace floor

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Accelerated corrosion near penetrations, probably caused by rain water leaking past penetration seal.
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Roof debris blocks drainage holes, trapping rainwater.

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BulkheadGasBypass

Hot Exh

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

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BentDrainsIndicateStress

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

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Casing
AccessDoors HotSpot

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PenetrationSeals

Bellows cracks can be difficult to see. Tight cracks, bellows are compressed when off line. Look for hot spots, and nearby insulation fur.
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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.
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HRST Upgraded Pipe Penetration Seal

PROBLEM: Tears in Fabric T i F bi Cracks in Bellows Delay box

SOLUTION: HRST Pipe Penetration Seals

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Casing Stress & Cracks

Expansion

Stress Points (Typ)

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Casing Stress & Cracks

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Casing Crack

Hotspots

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HRSGInspection
Water/SteamSideTasks

SteamDrumsaretheonlynonintrusiveaccess y tothewater/steamsideinamodernHRSG. Drumsareoftenalsoinspectedbythewater chemistrydeptandinsuranceinspector.

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Water/SteamSideInspectionTasks
SteamDrumChecklist 1. Drumsurfacecondition 2. Signsofdistressonsteamseparation equipment&bellypan 3. Thicknessofbellyplatesandsteam separators 4. MechanicalIntegrity g y 5. Approximatewaterlinevs.drawing 6. Debris
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DrumSurfaceCondition
1. Drumsurfacedetails(color,condition,pits)
Color
Redisgoodinanoxidizingenvironment Redisbadinareducingenvironment Keeptrackofsurfacedefectsfrommanufacture Trackwhethersmoothness(roughness)ischanging Doyouhavethem? Whatdotheylooklikeunderneath?

Condition

Pits Pits

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OxygenAttackinSteamDrum Offline

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HPDrumCondition

Surface defects in an HP drum from rolling steel NOT a significant issue 8/10/2009 Columbus, OH AEP / BRO Forum

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

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SignsofDistress
Cracks?

Baffle Cracks?

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HP BellyPanCracks (orbaffleplate)

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Downcomer Indications

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

N/EandCerrey
BellyPans(nocyclones)

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

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Cycloneswornthrough fromFAC

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BellyPanThinning UTinLP&IP Check here!

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LPBellyPanHole(FAC)

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MechanicalIntegrity
4. IntegrityofInternals i f l
Piping
BrokenUBolts Missingnuts PluggedChemFeedLines

Separators
Failure Plugging Missinghardware

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HP FallenChemFeedLine

U bolt broke off

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HPDrum ChemFeedLine

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HPDrum brokencycloneattachment

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Deltak PerforatedPlateAbove MeshSeparator

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Deltak MeshSeparatorFailure

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

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LP leveltransmitterproximity topumpsuction

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Debrisinleveltap

Lower level tap magnetic debris

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

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Debrisindrum

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

Exterior

Steam/WaterSide

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HRSGInspection
FurtherWork
OnlineorHotInspection
HRSGinspectionwhileunitisoperating Idealforfindinghotspots,casingcracks,penetrationsealfailures g p , g ,p Cancheckhotpositionofspringhangers

ExtendedScopeofflineinspection
Dependingontheage,quantity&severityofcyclesandhistoryofissues, moreintrusiveinspectiontechniquesmaybebesttoquantifycondition. Commontechniques:
1. 2. 3. 4. 5. 6. 7. 8. 9. UTtubesandpipingbeyondspotchecks(AScan,PhasedArray,orShearWave) DyePenetrant orMagneticparticletestingofsuspectareas ConventionalandDigitalXRay(Radiography) EddyCurrentTesting PipingAssessment HardnessandReplication(P91) Desuperheaterremoval&inspection Borescoping Tubesamples

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

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