Managing Boiler & Steam Cycle Pressure Part Integrity

Posted in Courses


This training course is primarily intended for experienced O&M staff working in thermal power and process plants, but could also be of interest to corporate engineering and management staff. The objective is to give attendees a comprehensive view of the strategy, actions and considerations involved in effectively managing and thereby assuring the integrity of piping, tubing and vessels that form the pressure boundary to steam or water process fluid. A range of topics relating to the design, inspection and repair of relevant components are treated using a combination of theory and numerous practical examples. The examples are all based on actual project cases encountered by Tetra Engineering staff at plants around the world.

Course Syllabus

Overview of Pressure Part Design and Components

Understand the key considerations involved in designing all the power and process plant components that form the pressure boundary.

  • Review of Design Codes and Standards for Tubes, Piping and Vessels
  • Design Criteria and Design Choices
  • Shop Fabrication and Field Installation Basics

Review of Damage Mechanisms

Gain insight into the theory underlying the most damage mechanisms that affect pressure boundary components, either on the waterside or fire/air-side.

  • General Surface Corrosion
  • Pitting
  • Flow Accelerated Corrosion and Fluid Erosion
  • Underdeposit Attack
  • Fatigue and Corrosion Fatigue
  • Creep and Creep Fatigue
  • Fire or Gas Side Erosion or Attack
  • Other Mechanisms (Hydrogren Embrittlement, Stress-Corrosion Cracking etc.)

Inspection and Surveillance

A survey of the inspection and surveillance techniques and practices that are available and how to best choose the best approach for assuring pressure part integrity over time while considering the impact of economic and operational constraints.

  • Setting the Strategy
  • Overview of Practical NDE Techniques
  • Field Inspection Practice
    • Covered Piping Systems
    • Boiler Tubes, Headers and Internal Interconnect Piping
    • Pressure Vessels and Tanks
  • How to Review Operating Data
  • Inspection Data Knowledge Management

Life Assessment & Failure Analysis

Learn about various methods to predict wear and damage in pressure parts as well as determine causes of failures.

  • Component Life Assessment Techniques
  • Overview of “Fitness-for-Service” Assessments
  • Guidelines for Performing Root Cause Analysis (RCA) on Pressure Part Failures
  • Combining Analysis and Inspection to Improve Condition Assessments

Repair of Pressure Parts

Learn about how to best plan and then perform repairs to meet the challenge of achieving schedule, cost and quality objectives.

  • Assessing Repair Options and Planning Repairs
  • Review of Available Welding & Repair Codes and Guidelines (ASME XI, PCC-2 etc.)
  • Assessing and Assuring Welding Quality
  • Special Materials (P91)
  • Tracking Repair History

Sample Case Histories and Discussion

Examples from recent projects performed by Tetra staff are presented, covering field inspections, life assessments and failure analyses on a variety of steam cycle pressure part components.

For  more information about this course please contact Christine Vallon, or call our European office at +33 4 92 96 92 54. Tetra offers courses on client site or as per our public course schedule

About Us

Established in 1989, Tetra Engineering has more than 25 years experience providing solutions to the power industry. We specialize in solutions for HRSGs, conventional boilers & steam-cycle balance of plant.