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ISSUE:
Boiler Biz
Considering an
HRSG Pressure
Test?
Manway Sealing
Part 3Gasket
Placement and Door
Closing
Finned Tube
Cleaning
New Additions to
the Team
Winter 2007
Upcoming Training
Courses
Volume 8 Issue 2
and create a torturous path for the steam flow. Dry steam
is able to navigate its way through the twists and turns
3 where as any suspended water droplets will impact the mesh
wires, coalesce and drip back down into the drum water.
The perforated plate behind the mesh pad serves two
4 purposes. First, it provides support for the mesh as the
steam flows through and second, it creates a pressure drop
large enough to ensure that steam flows through the entire
area of the mesh pad. Without this pressure drop steam
4 flow would concentrate in the portion of the mesh immediately below the steam outlet.
Make all welds between the perf plate and stiffeners within a 24 radius of the steam outlet full length welds
rather than skip welds.
Make the welds between the perf plate and the housing which supports the plate within 36 of steam outlet full
length welds.
Victor Ferris, P.E.
Copyright 2007 by HRST, Inc. All rights reserved.
For preheaters, economizers and evaporators, usually just filling the section with
water and relying on hydrostatic head is sufficient to reveal most tube leaks.
2.
For superheaters and reheaters, shutting the HRSG down with the drain lines kept
closed can help find leaks. Condensate accumulates in the lower headers, which can
submerge the lower tube panel (harp) tube welds, possibly revealing leaks.
3.
If possible, when entering an HRSG maintenance outage, keep the HRSG full of
water until the boiler inspector has had an opportunity to crawl through the lower
crawl spaces and access lanes. This improves the odds of the inspector noticing a
wet spot indicating a leak.
4.
For outdoor HRSGs, keep the roof doors closed until the lower crawl spaces and
access lanes have been inspected. This keeps out rain water making it easier to
notice wet spots from pressure part leaks.
5.
If there is freeze risk, be aware that sitting idle with an HRSG full of water can
be risky.
Applying more than hydrostatic head pressure on the boiler section means first
completely filling the boiler with water, including the superheater. This allows
pressure to be applied, forcing water out even tight, small cracks. This involves
careful consideration and more involved preparation steps.
2.
Superheaters operate full of steam, not water, so before flooding a superheater, research what pipe support
actions are required to handle the extra water weight.
3.
Which pipe support spring hangers need to be pinned? Do temporary fixed supports need to be installed?
Research what was required by the OEM when the pre-commissioning hydro test was performed during
erection.
Determine the acceptable pipe metal temperatures before pinning is permitted. Pinning spring hangers while
piping is still hot can cause unexpected pipe loading as the pipes continue to cool.
Consider developing a pressure test pipe support plan that can be used if a pressure test is needed. Utilize a
piping engineer who can analyze and recommend temperature limits to determine when spring supports can be
pinned, and where additional temporary supports may need to be added.
Can the superheater be filled with drum water, or is back filling with clean condensate required?
Back filling with clean condensate is definitely required if the superheater has any austenitic pressure part
sections, because of stress corrosion cracking concerns. Most HRSG superheaters do not use austenitic steels,
so filling with drum water may be acceptable since the water can be completely drained prior to start-up.
If the evaporator is on phosphate or caustic water treatment programs, pushing boiler drum water into the
superheater might cause steam turbine start-up delays due to high sodium.
Keeping the steam system clean to protect the turbine tends to be a high priority at most plants, so using clean
condensate piped directly to the superheater or reheater will help avoid putting silica, iron oxide or other
junk in the superheater
Continued on pg. 3
Page 2
4.
Do you have leaky valves? Probably so! With this in mind youll need to rely on looking and listening for leaks, rather
than watching a pressure gauge to find leaks.
5.
Decide in advance the maximum allowable temperature difference between the water entering a header or drum and
the components metal temperature.
Differentials up to 100 F are generally considered acceptable. Analysis may reveal higher allowable
temperature differentials.
6.
If the weather is cool, be careful to keep the HRSG pressure parts above 70 F.
Below 70 F, there is a chance of brittle fracture if applying serious pressure.
7.
Be prepared to look and listen for water leaks. Once youve gone through all the
effort of preparing and filling for a pressure test, dont skimp on the follow
through effort to inspect and listen for leaks.
8.
For HP systems, start with 100 psig pressure, and look from outside the
casing, through the manways, for obvious leaks.
Hopefully water is not raining down inside your HRSG! If all is dry, then increase pressure to 50% of HP drum operating pressure, and look for leaks
from the outside.
After holding at 50% of HP drum pressure for 20 minutes, reduce pressure to about 50 psig and send the
inspectors inside the HRSG to visually look and listen for leaks. Have your inspector do a thorough crawlthrough. You can use modern acoustic listening devices to aid your inspection.
Results:
a.
No leaks? Great, send an email to your boss that all the effort has decreased the risk of a tube leak outage
during the next peak season.
b.
Found a leak? Cancel dinner at home, order in a pizza (use a coupon to save money for repairs) and contact your
HRSG repair expert for repair planning advice! Also brag to your boss that you found the leak on your time
table rather than letting the leak find you right before your vacation!
c.
Finally, dont forget to properly drain the superheater and reheaters, remove spring hanger pins, remove
temporary supports, and disconnect temporary fill connections.
Pressure testing using low pressure air can be helpful, but well save that for a future newsletter.
Do you have a success story or preferred approach to finding tube leaks? Email me your tip or technique and if we use it
in BoilerBiz, or if we just find it interesting and creative, well send you a cool HRST monogrammed item from our
impressive collection of stuff.
Lester Stanley, P.E. (lstanley@hrstinc.com)
Page 3
Whichever door you have at your facility its important that the correct manway door gasket for the rated pressure
application, has been selected (see Boiler Biz, Volume 7 Issue 1, Spring 2007, Spiral Wound Gaskets). Elliptical Manway
gaskets can be easily placed in the drum by turning the gasket sideways. However the round manway gasket is not so
easy. Remember the city street worker??
In response to the need, HRST has developed boiler cleaning techniques to remove the
deposits from finned tubes. Within the last year, two different methods have been
used successfully to clean deep into tube banks. The tools and the techniques vary per
the design as the obstacles to cleanability are not the same for all OEMs.
Understand that this is a competitive business and HRST has made an investment in
developing this technology. So don't expect us to disclose every detail here. If
interested in learning more about whether these new cleaning techniques may apply to
your needs, contact your favorite HRST engineer and ask.
Patrick Walker
Page 4
If using a Flexible Spiral Wound Gasket it has to be deformed slightly to get it inside
the drum opening. Do not compress the Flex Gasket from the OD, as this can result in
too much flexing of the corrugations and damage the gasket. The preferred method is
to use a Bow and Arrow motion by gently grabbing the ID of the gasket with both
hands 180 degrees apart. This will stretch the gasket to get it in the drum. Check
with your gasket provider if there are new designs available that may be a better fit to
you.
The gasket is in the drum, whats next? Close the door, tighten it up and head for the
hills!!! This is another part of the drum manway closing that needs as much attention as
gasket selection. Drum manway doors all have some slack in them, meaning the door has
up and down movement because it pivots on a hinge. The door needs to be centered
with the gasket in position. Well, how do I do that correctly? One maintenance worker
told me he uses a Porta-Power Jack to center the door in the manway hole so he has
proper alignment on all sides of the door. That works, but who wants to carry a PortaPower to the top of the units, especially if you have multiple units. There is an
attachment that HRST has developed to help with this problem as can be seen in the photo above.
This device allows the individual closing the door to be sure there is an equal gap all around the door before tightening
the man-way bolts. Be sure to re-torque after the unit has been operating at full pressure and temperature (see Boiler
Biz, Volume 7 Issue 2, Fall 2006, Manway Sealing Part 2-Re-tourquing).
Dan Turley at Coyote Spring uses a PS-9400-G, Para Seal gasket obtained from Paramount Supply for his round
manways. Dan advises that the gasket seals well and can be easily fit into the drum.
Craig Dube
Copyright 2007 by HRST, Inc. All rights reserved.
Page 5
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