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8/10/2009 Columbus, OH
HRSGInspection
Goals:
1. Documentconditionofequipment 2. Identifyitemsthatneedimmediate maintenance 3. Identifyitemsthatneedbudgetingand planningformaintenancenextyear yp y, g 4. Identifyproblemsearly,allowingtimefor scrutinyandanalysis 5. Duediligence..showstakeholdersyouhave proactiveapproach.
8/10/2009 Columbus, OH AEP / BRO Forum 2
HRSGInspection
KeyElements 1. Dedicatedinspectors
Goodinspectionstakedaysnothours! Good inspections take days not hours! Photos,measurements,notes Everyfactshouldbeaccuratelylinkedtoaspecificlocation. Thickness(UT),Gapdistance,cracklength GasPath Steam/WaterSide Exterior
AEP / BRO Forum 3
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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
8/10/2009 Columbus, OH AEP / BRO Forum 4
8/10/2009 Columbus, OH
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.
AEP / BRO Forum 6
4. Baffles&TubeTies
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InletDuctLiner
Loose&brokencomponents
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InletDuctLiner
SpinningWashers
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InletDuctLiner
LinerGaps,ExposedInsulation
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FlowDistributionGrid
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TubeTies
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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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BurnerBaffleFailures
Coen baffle weld seam cracks & failures
Coen fix for baffle weld seam cracks & failures. May not be enough, some cracking still being found.
8/10/2009 Columbus, OH AEP / BRO Forum 15
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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.
8/10/2009 Columbus, OH AEP / BRO Forum 17
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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GasBaffles
Tubes
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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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Accelerated corrosion near penetrations, probably caused by rain water leaking past penetration seal.
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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.
8/10/2009 Columbus, OH AEP / BRO Forum 40
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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.
8/10/2009 Columbus, OH AEP / BRO Forum 41
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Expansion
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Casing Crack
Hotspots
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HRSGInspection
Water/SteamSideTasks
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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
8/10/2009 Columbus, OH AEP / BRO Forum 48
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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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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
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HPDrum ChemFeedLine
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HPDrum brokencycloneattachment
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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
8/10/2009 Columbus, OH AEP / BRO Forum 68
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LP waterlevel
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LP leveltransmitterproximity topumpsuction
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Debrisinleveltap
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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