HRSG-15 - HRSG Repairs - Kitterman

Bremco, Inc. Bill Kitterman

10/22/2014

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Tube Leaks  Panel Replacements 

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Stick thru with “J” bevel Socket Set Side Stick thru Set on Spot face set on Extruded header

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What section of unit ? Upper, Lower, or elsewhere Tube to header weld Header location (in a bundle or open)

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Raise, Lower Panel (Harps) Jack panels apart Cut your way in weld your way out Plugging

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Cutting jumper piping, drains, etc Restraints Stress Reliving (if necessary) Rigging

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Cutting restraints Cutting Drains Blocking

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Tube leak location: Tube 12 counting east from the HRSG center.

Gas Flow

4 feet (approx.) east of HRSG centerline.

Very narrow

Big wide

access lane, 20-24” wide. HPSH2

access lane. 5’ wide approx.

RH2

HPSH3

HPSH4

HPEvap

HPEvap

Downcomer Manifold

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Amount of tubes needed to be cut out Tube stock availability

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In our eyes least desirable method Strong Code involvement 

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P/T 91 Should involve engineered solutions because of ASME Section 1 requirements

Highest skill level needed Strong potential for stress reliving in 2 areas (Upper and lower headers) Possible circulation / flow concerns

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Header to Header  Involves “window” in Header sections plugging individual tubes on“removed” both upper and lower headers and replacing section of header, usually used when tubes are not readily accessed Tube to Tube / Header ( Gas Flow)  Involves plugging tube stub, or direct to header on both the upper and lower header. Requires access to tube/header in gas path . The preferred method for this repair should be a “dutchman” or a “pup” which would allow the tube to remain in the circuit

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Job Traveler Item Data Report ( P3,P4,P6,U1A Forms etc.) Weld Procedure and Supporting PQR Welder Qualifications with supporting Continuity Log. Material Receiving Report Mapping and/or Photo Documentation. Required NDE Certificate Documentation R-1, R-2 Form, of Compliance Bremco Inc,Canadian HRSG Forum

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P -1 

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When weld metal exceeds .750”(1.9cm) or base metal exceeds 1”(2.54cm).

P -4 ( 1.250 Chrome) P/T/F-11 

For post weld heat treat one of three conditions must be met   

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P –5A (2.250 Chrome) P/T/F-22 

For post weld heat treat one of the four conditions must be met    

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Base metal at weld exceeds .625”(1.59cm) in thickness Maximum specified carbon content exceeds .15% Base metals greater than or equal to .625”(1.59cm) are not preheated to 250 F (121C)

Maximum specified chrome content exceeds 3% Base metal thickness exceeds .625”(1.59cm) at the weld Maximum carbon content exceeds .15% Preheat of 300 F (149 C) is not used

P – 15E ( 9 Chrome) P/T/F-91 

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Stress reliving required for all applications


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Trials and Tribulations Understanding “TRUE” down times New material to old


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Relatively “new” material and applications has caused adjustments in weld/repair procedures Preheat and interpass temperature must be between 400 and 600 F. (204.5 – 315.5 C) Thermocouple design and placement is critical to success of weld New material to “old” material creates additional challenges

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Weld out is usually the shortest process 

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Wrap and thermocouple placement must occur before preheat can begin Preheat to get to proper temperature before welding can begin including soak time necessary Welding occurs Potential for rewrap/ Hydrogen bakeout procedure Post weld heat treat can start usually lasting anywhere from 12-14 hours Small bore valves ( could really extend time)


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Magnetism 

Not an uncommon occurrence weldors will see

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puddle “jumping” from side to side as they lay a bead in May require material to be “degassed”

Hardness of material 

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Old vs New


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Complete Modules 

Requires largest space requirements, also requires largest cranes (500T +) (453MT) based on module size and location of crane placement

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Panel Replacements 

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Typically requires smaller crane (125T )(113MT) as panel size is up to 50,000 lbs (22.68 KG)

Build in Place 

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Utilized when crane is either impractical or space considerations just don’t allow. Bremco Inc, Canadian HRSG Forum

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Most Challenging based on skill sets needed  Requires smaller crane  Takes up less plant footprint

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Planning Scope Identification 

Identifying areas of concern 

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Material lead time Outage duration Coordination issues 

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Laydown areas Resources  Cranes/Lulls/Forktrucks etc  Facilities, Utilities


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Turnkey or Multivendor 

Turnkey one contact one voice but typically higher

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priced Innovative solutions Multivendor

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Coordination issues and supply delivery concerns (multiple voices) Possibly less communication between vendors


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Time to plan next year’s outage is while you are in this one. Delivery on panels etc. historically run 18-26 weeks but we have seen lead time as long as 48-52 weeks depending on material grade etc.

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Questions

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HRSG-15 - HRSG Repairs - Kitterman

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