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HRSG Pressure Part Replacements and Repairs

This seminar is primarily intended for HRSG Owners, Asset Managers, and O&M Management but will be useful for almost anyone working with Combined Cycle or Cogeneration Plants with Heat Recovery Steam Generators. HRSGs have generally high reliability with regard to pressure parts including tubes, piping and headers but inspection, testing and repairs are more difficult and time consuming than in other boilers. In many cases by the time leaks are evident, damage to the tubes, tube panels (HARPS) and tube modules can be widespread.    Repairs can require complete replacement of HARPS and/or entire tube modules.  These require advance planning and procurement to be done successfully in an operational HRSG. Extensive repairs and replacements can also be required due to defects in fabrication, construction and commissioning or from accidents such as gas turbine fires and explosions. Tetra Engineering has supported plant owners, operators and others in these major events for many years.   We have supplied forensics, engineering oversight, due diligence, factory and erection oversight and support for owners in disputes worldwide   This seminar will be presented by experienced instructors in all these areas.

Seminar Syllabus

Introduction and Overview

  • HRSG Basics (major components, design options, variants)
  • Why Modern HRSG’s Present difficulties for major repairs and replacements
  • Pressure Part Failures in HRSGs and Impact on key reliability and availability metrics

Causes of HRSG Pressure Part Failures

  • Key Types of Failures
  • Failures from Fabrication Quality issues
  • Failures during Commissioning
  • Failures from operational issues (corrosion, fatigue, overheating and others)
  • Failures from Other Causes.

HRSG Life Management for High Reliability and Availability

  • Monitoring, Inspection and Useful Remaining Life Assessment
  • Consideration of Operational Changes (Cycling, Low Load, Flexible Operation, Alternate Fuels)

HRSG Pressure Part Repair and Replacement Options

  • Individual Tube Replacement/Plugging/Repair
  • Tube Panel Replacement (Single HARP or Selected HARPS)
  • Tube Module Replacement

Engineering, Procurement, Replacement Actions for HRSG Pressure Parts

  • Specification Development for replacement or upgrade and replace options
  • Re-Engineering Considerations
  • Procurement and Installation Options (Single Source OEM, EPC or Split Contracts)
  • Typical Schedule and Price Issues (local or off-shore sourcing, fabrication options, construction management)
  • Project Supervision and Oversight

HRSG Pressure Part Replacement Case Studies

  • Extensive Design/Fabrication Quality Issues in New Plant
  • Partial Replacement of Evaporator Tubes
  • Full Replacement of Evaporator Modules
  • Replacement of Tubes Damaged in Turbine Accidents 
  • Partial HARP replacements
  • Issues in Replacement Access

USA Courses: To register or for more information, please contact Natalie Vasa, at our offices in the United States This email address is being protected from spambots. You need JavaScript enabled to view it. or +1 (860) 651-4622 ext. 102.

Europe/Middle East/Asia Courses: Please contact Christine Vallon for registration or information purposes at This email address is being protected from spambots. You need JavaScript enabled to view it.or by telephone on +33 4 92 96 92 54.

Refer to individual course syllabus for terms and conditions. Tetra Engineering reserves the right to cancel, in our sole discretion, any course 4 weeks prior to the respective start date.