2014 Canadian HRSG Users

Group Presentation
Casing penetrations

October 20th 22nd - Claude Chiasson

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Sarnia Plant

The Sarnia plant has three Nooter Eriksen

HRSGs c/w Alstom 11N2 gas turbines.

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History
We have seen some water staining (rusting)
at the top of some bundles during gas side
inspections which prompted me to inspect
the roof seals.
The build up of debris over time in the floor
seal bellows is well understood (or should be)
and inspection did reveal that corrosion is
occurring on the O.D. of the drain lines.
Casing bottom penetration seal bellows - typical
Note the drain holes on the bottom flange area of the bellows. The OEM
design was two 1.6 mm holes 180 degrees apart; these were increased to
6.35 mm a few years agobut we still get some pluggage.
Plan view of HRSG drains
Seal bellows 30 total.
Typical shadow shot radiograph.
We performed this inspection in preparation for major outage. Scaling
can be seen on the OD of the drain line inside the bellows.
Typical shadow shot radiograph.
Another example clearly showing the scaling on the OD.
As found condition after removal of the bellows
Note washer on the inside of the casing plate.
Drain lines after cleaning by power brush.
Close up of drain line after cleaning with power
brush.
Although all lines have considerable general corrosion, some are worse
than others.
Casing bottom penetration seal bellows - typical
Note the drain holes on the bottom flange area.
Roof penetrations
Improperly insulated in my opinion.
Plan view of HRSG roof penetrations.
Nozzles that need to be seal welded.
As found condition to LP drum
As you can see, insulation that has gotten wet sticks to the metal and
requires time to properly remove/clean.
As found condition to HP drum
I was expecting to find some problems with the gasket under the bolted
packing flange but what we found was that the original required seal
weld was never done.
Original seal weld detail.
Was not completed at the time of construction.
Typical roof nozzle
Thickness readings taken.
Final repair
Examined by the black on white magnetic particle method.
Reinsulated after repairs.
Reinsulated after repairs
Stand off from the casing roof to prevent wicking of water.
Reinsulated after repairs
Cladding down to the casing roof.