Previous Projects

With over 30 years of experience in power and industrial steam generation services, Tetra Engineering has along history of projects.

Selected recent Global Technical Projects are summarized and presented in this section

For more information on any of these projects or Tetra capabiltites contact your regional Tetra office here.

HP Bypass Finite Element Analysis, 2015

Tetra was engaged by a client to perform a finite element analysis of the HP Bypass valve reducer, using measured displacements as input. Results from a strain gauge/displacement survey showed a large strain effect occurring during the start-up of the boiler. Initially, both the left and right side strain gauges on the reducer showed compressive strain. During the start something triggered the reducer to experience tensile strain that differed in its intensity between left and right. The purpose of the study was to try to simulate the observed strain fields and determine the root cause.

Client region: Europe

Site Condition Assessment, 2015

A Tetra Senior Engineer visited a south east asian power plant site to make an assessment of the commissioning situation. The EPC engaged Tetra as they considered that their site work was being delayed due to lack of progress by the IPP to perform their scope of work.There was significant lack of communication between the two parties as well as discrepancies in the scope of work, which lead to schedule delays and cause of mutual blaming between parties.

Client region: South East Asia

High Energy Piping (HEP) Remaining Life Assessment (RLA), 2015

Tetra was hired by a client to investgate the remaning life of the HEP on 3 units of a thermal power station. The plant intended to operate the units for another 100,000 hours. The scope of work entailed a piping stress analysis of the main steam and hot reheat lines, thermal stress analysis of the SH header outlet/main steam line and remaining life assessment (creep, fatigue, creep-fatigue) of critical areas based on inspection history and results from the pipe stress/finite element analysis. The figure shows time-dependent stresses and temperatures during start up.

Client region: Europe

Study of impact of cyclic loads on superheater tubes, 2015

During the shutdown of the unit at night, the HP bypass was kept open to maintain a vacuum in the steam turbine condenser in order to guarantee a faster start the next morning. Therefore, a small quantity of high pressure steam from the HP drum was flowing through the SH on the way to the HP bypass valve. The small HP steam flow takes the path of least resistance and only goes through tubes on one side of the unit, affecting their temperature. The temperature of the tubes on the other side change differently and a temperature difference of around 80°C can be seen 2 hours after shutdown. The CCGT owner engaged Tetra Engineering to investigate the impact of these resultant cyclic loads on the fatigue life of the tube to header welds. The study concluded that the temperature difference of 80°C between different tubes does not cause high enough fatigue stresses alone to be considered critical

Client region: Europe

Superheater Tube Root Cause Failure Analysis, 2015

Tetra Engineering completed a Tube Failure Analysis of failed SH tubes from a CCGT plant in South East Asia. The results show the following damage mechanisms present:

  • Short-term Creep and Fatigue damage (Creep-Fatigue interaction)
  • Short-term Creep and Stress Corrosion Cracking (SCC) or Hydrogen Embrittlement

The fact that short-term creep damage was observed on both of the failed tubes indicates a sudden change in temperature. It was possible that newly discovered damage to the turbine exhaust flow correction device could have allowed a larger mass flow to one side of the boiler (due to swirl influence), increasing the tube temperatures locally and/or increasing local stresses when expansion is prevented, thus accelerating creep damage. The plant had suffered from frequent fatigue failures, with several independent metallurgical analyses over the years confirming thermal fatigue as the previous root cause. No signs of any creep damage had previously been discovered.

Client region: South East Asia

CFD Study of HRSG Gas Path, 2015

Tetra Engineering  performed a CFD analysis of the HRSG gas path at a CCGT in Asia in collaboration with CFD specialist R&R Consult. The results showed a very uneven flow distribution at base load over the HPHTSH tube sheet, with a higher mass flow located towards the outlet header sections and towards the side walls. The swirling motion of the GT flow results in a different flow pattern for the low load case, compared to the base load case. The flow was more evenly distributed in the longitudinal direction at the SH, but a considerable variation is seen in the span-wise direction. The uneven flow distribution was thought to be a contributing factor to the repeated fatigue failures seen in the boiler over the last couple of years.

Client region: South East Asia

Field Assessment of Piping Water Hammer Event, 2014

Tetra Engineering was asked to assess the situation after a significant water slug/hammer event. Observations made during the site visit showed that the structural members were severely damaged with steel being heavily deformed and torn in some cases.  Piping supports were also severely damaged and would require repair.

Client region: Middle East

LP EVAP Tube Failure Analysis, 2014

Tetra Engineering was asked by a client to help to assess the cause of tube failures in the upper section of the LPEVAP on their HRSG units. The first tube failure was reported in 2010; other failures have followed since then at a rate of two to three per year. At the time of the first failure the plant had been operating for approximately three years. Tetra performed a root cause analysis which included a review of water chemistry logs, boiler simulations using PPSD as well as a FAC Risk Assessment.

Client region: Middle East.

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