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HRSG SERVICE SOLUTIONS

HRSG inspection services

Risk management to secure your investment

Alstom inspects HRSGs from virtually all OEMs. We combine our experience, thoroughness and proven processes to deliver quality inspection services during planned and forced outages.

Advanced technology, local presence


The heat recovery steam generator (HRSG) represents a significant portion of the total plant investment and overall efficiency of the plant. Through regular inspections, problems can be detected at an early stage, thus ensuring longevity and preventing damage and unplanned outages. As a leading power original equipment manufacturer (OEM) and service provider, Alstom offers specialist inspection and support services to help plant owners optimise operational strategies and reduce the total lifecycle costs of their HRSG.

SERVICES FEATURES BASIC INSPECTION SERVICE

Visual inspection of pressure parts, gas path, steel structure and piping. Evaluation of the results by the Alstom engineering support group. Inspection report with recommendations.

ADDITIONAL OPTIONS INCLUDE

Pre-outage walk down Thermographic surveys Specialist non-destructive examinations Information management
CustOMer BeNefits

Increased availability and reduced risk

Via regular inspections that help to identify current and future areas of concern, priorities can be set and maintenance and repair plans optimised

Longevity

Alstoms advanced analysis capabilities and engineering experience help to extend the HRSG lifetime

Maximum know-how transfer


Inspections, repairs and engineered solutions, for HRSGs and other plant equipment, from a single provider with extensive OEM and field service experience

TPW/BPROS/HRSGINSPSERV/eng/COMTPW/11.12/CH/7788 ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Alstom contributes to the protection of the environment. This leaflet is printed on environmentally-friendly paper.

A GLOBAL LOCAL TEAM

Alstom has an extensive network of field service engineers to assist with your outage inspections. Our strategic locations worldwide facilitate rapid emergency and cost-effective planned responses. Thanks to professional foundations and regular training courses, all our inspection engineers and technicians are equipped with best practice knowledge and cutting-edge technology to ensure accurate inspections, insightful analysis and reliable recommendations. We can also support or carry out the recommended maintenance measures, needed immediate repairs or longer term improvements.

ALIGNING INSPECTIONS FOR OPTIMISED AVAILABILITY

In order to prevent forced outages, periodic inspections should be conducted during scheduled outages. This allows the identification of component damage in the earliest stages when there is still time to schedule a cost-effective repair. Alstom recommends a general inspection every 1 to 2 years and a more detailed inspection every 3 to 5 years. In order to optimise the over-all plant availability, it is important to align these inspections with those of the gas turbine. Therefore the detailed inspection should coincide with a gas turbine planned outage of one week or longer, e.g. the C-inspection (for Alstom turbines) or the major or hot gas path inspection (for GE, Siemens and other manufacturers turbines). Between the detailed inspections, at least one general inspection should be planned, e.g. the B-inspection (for Alstom turbines) or the combustion inspection (for GE, Siemens and other manufacturers turbines). Depending on the gas turbine outages and the general HRSG condition, this can also be an annual inspection.

B-inspection interval 1 - 2 years

C-inspection interval 3 - 5 years

Gas turbine inspections

B
Combustion

C
Major / Hot gas path

B
Combustion

C
Major / Hot gas path

HRSG inspections

General inspection
2 - 3 days

Detailed inspection
4 - 6 days

General inspection
2 - 3 days

Detailed inspection
4 - 6 days

SCOPE OF THE INSPECTIONS GENERAL HRSG INSPECTION


A visual survey of the general HRSG condition, external casing, internal gas-side mechanical parts and auxiliary equipment. Readily accessible pressure part components are visually inspected. Alstom recommends performing such a general inspection in addition to the basic inspections stipulated by local regulatory requirements. Time frame requirement: 2-3 days of HRSG accessibility.

DETAILED HRSG INSPECTION

Includes all the general inspection steps plus a more detailed visual inspection of all accessible pressure parts. This visual inspection will identify any areas of concern that require subsequent non-destructive examination (NDE) to be performed by a qualified NDE technician. Time frame requirement: 4-6 days of HRSG accessibility.

HRSG SERVICE SOLUTIONS HRSG InsPECtion SErviCEs

ONE STOP FOR ALL YOUR HRSG INSPECTIONS AND ASSESSMENTS BASIC SCOPE OF INSPECTION SERVICES

Visual inspection of pressure parts, gas path, steel structure and piping Evaluation of the results by the Alstom engineering support group Inspection report with recommendations
RECOMMENDED EXTENDED SCOPE OF INSPECTION SERVICES
Pre-outage Walk down and punch list report based on findings and interviews Thermographic survey to review casing and piping and identify leaks or faulty insulation Recommendation for NDE tasks to be performed during the detailed HRSG inspection (NDE to be performed by a qualified NDE technician.) Outage planning support

Supervision of repair or installation works Visual inspection of desuperheaters, blow down system, deaerator and valves Review of any critical indications from the NDE inspections carried out during the detailed HRSG inspection Documentation and evaluation of the inspection results in CA-PRO , Alstoms webSM

During the outage

based HRSG lifetime information management system for efficient HRSG condition optimisation

Walk down to identify start-up problems


CONDITION ASSESSMENT SERVICES
To provide a genuine one stop option for all your inspection and assessment needs, Alstom also offers basic or advanced NDE/DE techniques to support inspections or follow-on repair works including: Phased array Radiography Surface replication Metallurgical tube sample analysis Boat and core sample analysis Alloy identification Other appropriate tests

Post-outage

SpecialiSed HRSG condition assessment


Header inspection robot

Specialised visual inspection sled to inspect headers for signs of Flow Accelerated Corrosion (FAC) Phased array butt-weld scanner Specialised device that uses phased array ultrasonics, combined with an encoded circumferential scan, to check the quality of butt welds on manual TIG / orbital pipe welds with diameters from 1.5 to 4.5 Water chemistry review / corrosion assessment Corrosion risk assessment based on design, historical chemistry readings, applied chemistry concept and operation profile Root cause analysis For specific problems
Phased array butt-weld scanner

HRSG SERVICE SOLUTIONS HRSG InsPECtion SErviCEs

ALSTOMS PLANT SYSTEMS EXPERTISE


Alstom offers criticality analysis support as an input into plant asset management systems, such as reliability-centred maintenance (RCM) or risk-based maintenance (RBM).

ON-SITE CRITICALITY ANALYSIS

OPTIMISING OPERATIONS IN CHANGING CONDITIONS

In some markets, changing energy mixes have made production demand more volatile, forcing operators to develop new flexible operational strategies. Increased cycling and part load operations subject HRSGs to more frequent transient mode stresses and accelerated fatigue or corrosion damage. Alstoms HRSG systems experts can help you optimise the interactions between gas turbine and HRSG operations to maximise longevity and performance.

For more information please contact Alstom Power: ALSTOM Power Inc. (US) Windsor, CT 06095-0500 United States Telephone: +1 860 285 2100 Toll Free: +1 866 257 8664 Fax: +1 860 285 3101 ALSTOM Ltd. (UK) Power House, Silverlink Business Park, Wallsend, Tyne & Wear NE28 9ND United Kingdom Telephone: +44 (0)191 295 2100 Fax: +44 (0)191 295 2011 Visit us online: www.alstom.com

TPW/BPROS/HRSGINSPSERV/eng/COMTPW/11.12/CH/7788 ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Alstom contributes to the protection of the environment. This leaflet is printed on environmentally-friendly paper.

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