Resources

Consult our range of free resources.

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Technical Guides

Tetra has published a series of guides which are available for ordering.

HRSG Inspection Planning Guide (2nd Edition)

Inspection is part of routine maintenance for any Heat Recovery Steam Generator (HRSG). Visual inspections are performed at regular intervals in accordance with the requirements of regulatory bodies and insurers.Inspection is part of routine maintenance for any Heat Recovery Steam Generator (HRSG). Visual inspections are performed at regular intervals in accordance with the requirements of regulatory bodies and insurers.

HRSG Tube Failure Diagnostic Guide (3rd Edition)

Heat Recovery Steam Generator (HRSG) tubes provide the media for extraction of useful energy from the waste heat in gas turbine exhaust at combined cycle power plants (GT-CCs) or from heat generated by process streams at petrochemical facilities.

Technical White Papers

A selection of technical papers available for reference.

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HRSG Inspection Planning

HRSG Inspection Planning

Building a good inspection plan for the HRSG involves doing the following: Set the Time and General Schedul...

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Welding Procedure Specification (WPS)

Welding Procedure Specification (WPS)

Before any welding activity can commence, the welder and the QC Engineer has to be fully aware of the content ...

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Post Weld Heat Treatment (PWHT)

Post Weld Heat Treatment (PWHT)

Post Weld Heat Treatment (PWHT) Background Post weld heat treatment is a post welding heating process used t...

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Power Boiler Piping

Power Boiler Piping

Boiler piping design requirements is divided into internal and external jurisdictions. These are divided...

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Creep Classification of Grade 91 Steel

Creep Classification of Grade 91 Steel

Background Grade 91 steel is superior to many other industry used materials for its increased resistance to m...

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Remote Visual Inspection (RVI), or Borescope

Remote Visual Inspection (RVI), or Borescope

One of the first applications of the borescope was for inspecting steam turbine rotor discontinuities in the 1...

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To discuss how we might assist you to improve your plant's performance or to maintain its value over time

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Papers, Presentations and Articles

Selected papers, presentations and articles from major industry conferences and events.

Title
Author
What do HRSG tube failure statistics tell us?
What do HRSG tube failure statistics tell us?What do HRSG tube failure statistics tell us?
Misha Gadher & Mark Taylor
Modern Power Systems
Counterfeit, Fraudulent and Suspect Items (CFSI) – Steel and HRSGs
Counterfeit, Fraudulent and Suspect Items (CFSI) – Steel and HRSGsCounterfeit, Fraudulent and Suspect Items (CFSI) – Steel and HRSGs
Taylor M.
IMechE HRSG User Group 2022
Adapting Existing Thermal Desalination Plants to Produce Hydrogen
Adapting Existing Thermal Desalination Plants to Produce HydrogenAdapting Existing Thermal Desalination Plants to Produce Hydrogen
Malloy J.
2022 World Utilities Congress
Root Cause Failure Investigation of MSCV Drain Failures
Root Cause Failure Investigation of MSCV Drain FailuresRoot Cause Failure Investigation of MSCV Drain Failures
P. Jackson, A. Wholey, E. Tsai and D. Burns
ASME 2022 Pressure Vessels & Piping Conference
Predicting and Preventing Risk of Vibration Induced Failures in Boilers and Heat Recovery Steam Generators (HRSG)
Predicting and Preventing Risk of Vibration Induced Failures in Boilers and Heat Recovery Steam Generators (HRSG)Predicting and Preventing Risk of Vibration Induced Failures in Boilers and Heat Recovery Steam Generators (HRSG)
Fabricius A., Malloy J., Taylor M., Moelling D.
Proceedings of the ASME 2022 Power Conference

Previous Projects

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

Flow Accelerated Corrosion Risk Assessment, 2017
South East Asia

Flow Accelerated Corrosion Risk Assessment, 2017

An assessment of the susceptibility of HRSG piping components was performed according to Tetra Engineering’s FACRisk™ methodology which includes the use of thermal modelling simulation software (PPSD). From each system, sub groups are ranked using both time to minimum wall thickness and wear rate. The highest risk components (such as elbows, tees and valves) are identified. Overall, due to relatively high operating pH level (>9.2), the overall risk of FAC failures at the CCGT plant in question was considered to be relatively low, with few specific areas showing increased risk. Three separate load cases were simulated and analysed to determine the potential FAC risk. The results of each simulation were incorporated into the final locations recommended for inspection.

Boiler Tube Failure Root Cause Analysis, 2017
Asia

Boiler Tube Failure Root Cause Analysis, 2017

After several tube failures in recent years in the 1st row of LTRH hanger tubes, Tetra was tasked with performing a Root Cause Analysis (RCA) to determine the underlying cause of the failures. A detailed review of operating data, failure reports and design information was carried out and potential causes investigated. The tube failure mechanism as determined by metallurgy was short-term overheating, with temperatures likely exceeding 700°C prior to failures. Two contributing causes were identified by elimination of all other possibilities: temporary loss of steam flow in affected leading row tubes coupled with high flue gas temperatures in certain tubes at the side of the boiler gas path.  Unfortunately, the underlying root cause of the loss of flow could not be confirmed, whereas the asymmetric flue gas temperature distribution is a known issue since commissioning.

HP Evaporator Tube Failure Analysis, 2016
Middle East

HP Evaporator Tube Failure Analysis, 2016

During a recent condenser tube leak at a CCGT Power Station in the Middle East, two trips occurred on the boiler feedwater pumps leading to trips of one of the HRSGs.  During that time, three tubes failed on the HP Evaporator. Tetra Engineering performed an investigation into the failures with the aim of determining the failure mechanism, to estimate the root cause of failure, and to identify inspection priorities in case damage may have gone undetected. This work included metallurgical analysis and a review of key operating data. Failures were located directly under the risers at extreme ends of the HP Drum. The most probable source of tensile overload is tube quenching when flow restarted

Attemperator Sleeve Failure Study, 2016
Europe

Attemperator Sleeve Failure Study, 2016

In 2015, it was discovered that the thermal sleeve in the attemperator in a client’s power station hot reheat line had failed, resulting in fracture around the circumferential weld in the sleeve’s mid section. For this reason, Tetra was engaged by the owner to investigate. The investigation showed failure from fatigue cracking. There were no signs of thermal fatigue damage, hence quenching from over-spraying was discounted as the root cause. The cracked area showed signs of high cyclic local strain, and given the moderate number of starts low-cycle fatigue was thought to be the root cause. Differential thermal expansion between the Grade 22 sleeve and the Grade 91 pipe, combined with lock-in of the sleeve on the pin locations, would raise sufficiently high stresses

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