Tetra Engineering has announced its schedule for HRSG & Combined Cycle training events in 2016. This year we will be hosting training courses in Utah and Connecticut, USA, as well as in France and a new event in Dubai, UAE. See our training page for more details.
Tetra Engineering provides services to assist Cement Plant Owners and Operators in implementing, maintaining and improving all types of Heat Recovery Systems. Our Heat Recovery Steam Generator and steam cycle services have been applied to Rotary Kiln Waste Heat recovery power generation systems. Whether addressing problems with fouling, or assessing plant modifications for performance improvements, contact Tetra to reduce your energy costs and increase reliability.
Tetra Engineering will be presenting our technical paper on "Impact of Startup Purge Credit on Combined Cycle Plant Operation" at the ASME Power and Energy Conversion 2015 Conference in San Diego, California, USA on June 30, 2015. It describes the technical basis for purge credit operation and provides an example of the impact on fatigue lifetime in key Heat Recovery Steam Generator components.
See the full program at the ASME website here.
ASME B31.1 places practice requirements on Operators for the maintenance of their Covered Piping Systems (CPSs). Condition Assessments are required on a regular basis, associated with good record-keeping for traceability. Over time this generates large volumes of documentation and inspection history data, therefore a coherent solution to knowledge management is needed.
PipeVue 2.0 was developed by Tetra Engineering to store and organize large amounts of inspection data in one network-based solution, easy accessible for both plant operators as well as engineers planning yearly inspections. PipeVue 2.0 has three modules covering:
- Pipe Hangers & Supports;
- Flow-accelerated Corrosion inspection data; and
- Grade 91 Weld inspection data
The software stores hanger/support setting information (hot/cold), inspection notes, photos, NDT data and associated design documentation (PDF drawings & manuals) in a simple and categorized manner, with 3D-visualization of all components.
The user can add new data and save to a networked database, where it will be instantly accessible for other users. The software is available as a deliverable from Piping Inspections, or independently as a Knowledge Management System for Power Piping. Engineering support from Tetra is available as an option, creating an instant channel between plant personnel and third party engineers.
Tetra Engineering will have a booth next month at the upcoming PowerGen Middle East in Abu Dhabi on October 12-14. We will present our latest service offerings including Field Services, Engineering Analysis, 3rd Party Engineering, and Training. Come see us at the N21 booth, and enter your business card for your chance to win a Wilesco Steam Engine Generator!
Announcing Tetra Engineering's Fall 2014 USA Training Seminar: Effective Operation of HRSGs on November 12 & 13 at The Simsbury Inn, Simsbury, Connecticut USA. See this link for more information on the syllabus.
The modern power generation market is very different to what it was ten or even five years ago. The requirement to provide network load flexibility is falling on combined cycle plants with HRSGs, they are having to fill the supply gap between base loaded nuclear and large coal plants and the highly variable renewable energy generators. The result of operating at lower loads means the HRSG operating conditions may be very different from what was envisaged in the design case. Equally the increased number of startups and shutdowns presents problems for components designed for baseload. The problems faced by plants that are cycling or operating at off-design conditions can include:
- Water chemistry instability due to transient conditions
- Quenching problems in superheater and reheater tubes during condensate formation
- Attemporator and Bypass Spray problems handling increased demand
- Economiser shock
- High temperatures at superheaters and reheaters leading to creep failures
- Higher heat flux in the HP Evaporator leading to increased deposit loading
- Increased FAC risk due to increased heat at the LP Evaporator
Tetra develops inspection plans to address these and other issues using:
- Visual Inspection of the HRSG hot gas path
- Borescope/videoscope inspection of waterside conditions of lead high-pressure (HP) evaporator tube panels and other areas
- Ultrasonic testing (UT) of wall thickness for selected (high-risk) tube, header, and riser components
- Magnetic particle testing of all accessible tube-header weld connections in the HP steam and reheater tube panels
- UT shear wave or UT phased-array inspection of Grade 91 components
- Visual inspection of accessible HRSG waterside components
- External walkdown and thermography
Flow-Accelerated Corrosion (FAC) or Erosions-Corrosion remains a common cause of failure in HRSGs and conventional boilers, yet the underlying causes and solutions have been well understood for more than 25 years. The two factors influencing the susceptibility to FAC are: a) Unit Design and b) Process Conditions. It is important to know how FAC-prone your HRSG or boiler design are, this will help you optimise your operating conditions to suit that design.
When assessing design factors, the primary question is whether the HRSG/boiler tubes and pipes' geometries and materials are suited to their flow profiles across the range of operating load cases. Operational factors are primarily concerned with assuring good control of water chemistry parameters (pH, dissolved oxygen or ORP, iron levels).
Since 2007 the ASME B31.1 Power Piping Code has included Chapter VII, establishing mandatory requirements for Operation and Maintenance. The key elements of this program are discussed here, and require that Operators outline a detailed maintenance plan for their Covered Piping Systems (CPSs). The Code also requires that operators perform regular Condition Assessments of their CPS ensuring that relevant degradation mechanisms are being covered.