1 HRSG Inspection Tasks Presented By: Bryan F. Craig, P.E HRST Inc. AEP / BRO Forum 8/10/2009 Columbus, OH 1 HRSG Inspection Goals: 1. Document condition of equipment 2. Identify items that need immediate maintenance 3. Identify items that need budgeting and planning for maintenance next year 4. Identifyproblems early, allowing time for scrutiny and analysis 5. Due diligence…..show stakeholders you have proactive approach. AEP / BRO Forum 8/10/2009 Columbus, OH 2
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1
HRSG Inspection Tasks
Presented By:Bryan F. Craig, P.EHRST Inc.
AEP / BRO Forum8/10/2009 Columbus, OH 1
HRSG Inspection
Goals:
1. Document condition of equipment
2. Identify items that need immediate maintenance
3. Identify items that need budgeting and planning for maintenance next year
4. Identify problems early, allowing time for y p y, gscrutiny and analysis
5. Due diligence…..show stakeholders you have proactive approach.
AEP / BRO Forum8/10/2009 Columbus, OH 2
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HRSG Inspection
Key Elements
1. Dedicated inspectors• Good inspections take days not hours!• Good inspections take days not hours!
– Thickness measurements are a useful tool to document condition of drum internals, tubes and ,piping.
– Be specific about locations & documentation
– Most measurements are simple thickness for general documentation or to track Flow Accelerated Corrosion
h d d f k d– More sophisticated UT used for crack detection: shear wave, phased array
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Cyclones worn through from FAC
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Belly Pan Thinning –UT in LP & IP
Check here!
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LP Belly Pan Hole (FAC)
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Mechanical Integrity
i f l4. Integrity of Internals
– Piping– Broken ‘U’ Bolts
– Missing nuts
– Plugged Chem Feed Lines
– Separators– Failure
– Plugging
– Missing hardware
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HP – Fallen Chem Feed Line
U bolt broke off
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HP Drum – Chem Feed Line
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HP Drum – broken cyclone attachment
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Deltak – Perforated Plate Above Mesh Separator
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Deltak ‐Mesh Separator Failure
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Approximate Water Line vs. Drawing
i di5. Water Line Readings
– The water line is often falsely reading low due to –proximity of the downcomer or pump suction to the level transmitters. The suction effect of those large lines ‘pulls’ on the level sensing lines.
– Plugging of the lines is problematic if they are positioned off the bottom of the shell.
– The number one cause of faulty level indication or control is calibration or compensation
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LP – water level
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LP – level transmitter proximity to pump suction
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Debris in level tap
Lower level tap magnetic debris
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Debris in Drums
6 b i6. Debris
– Amount
– Color
– Magnetite vs. Hematite?
– Flakes vs. Powder?
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Debris in drum
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• Gas Side – Access Lanes (inlet duct, firing duct, SCR, between tube
• Steam/Water Side– Steam Drums are the only non‐intrusive access to the
water/steam side in most HRSGs
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HRSG InspectionFurther Work
• Online or “Hot” Inspection– HRSG inspection while unit is operating– Ideal for finding hotspots, casing cracks, penetration seal failuresg p , g , p– Can check hot position of spring hangers
• “Extended Scope” offline inspection– Depending on the age, quantity & severity of cycles and history of issues,
more intrusive inspection techniques may be best to quantify condition.– Common techniques:
1. UT tubes and piping beyond spot checks (A Scan, Phased Array, or Shear Wave)2. Dye Penetrant or Magnetic particle testing of suspect areas3. Conventional and Digital X‐Ray (Radiography)4. Eddy Current Testing5. Piping Assessment6. Hardness and Replication (P91)7. Desuperheater removal & inspection8. Borescoping9. Tube samples
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Any Questions?
Bryan F. Craig, P.EHRST [email protected]‐855‐4688 (office)612‐743‐1009 (cell