We perform engineering analysis to improve boilers. Typical projects include Performance Evaluation, FAC Risk Assessment, Root Cause Failure Analysis and HRSG Cycling Assessment.
Performance Evaluation – We specialize in HRSG performance evaluation. HRST has developed a method to best fit performance data, allowing efficient identification of bad data, which then allows improved overall analysis accuracy. We can strategically locate test instrumentation to cost effectively supplement control room data. We produce a computer model of the boiler that indicates how each section is performing and highlights exactly where any shortfalls are occurring. Finally, we can predict the performance improvement that will be achieved by repairing shortcomings, and evaluate the economic impact of the retrofit improvements.
PDF Brochure: Performance Analysis and Monitoring
Flow Accelerated Corrosion Risk Assessment - Flow accelerated corrosion (FAC) is a damage mechanism that causes metal losses and failures in water piping, HRSG tubing, steam drums, and other components composed of carbon or low alloy steel. It is one of the top two most prevalent causes of pressure part damage in HRSGs (per EPRI Heat Recovery Steam Generator Tube Failure Manual dated May 2002). Developing an FAC monitoring plan is a prudent practice to help avoid damage and failures. Our approach is to prioritize the risk areas within an HRSG so that a client can optimized their monitoring plan by testing the high risk areas first. This lowers field testing costs, but more importantly, helps find problem areas before failures. Prioritization is performed based on design review, performance modeling; plus our boiler design and field experience.
PDF Brochure: FAC Risk Assessment
Root Cause Failure Analysis - Tracking boiler problems back to the root cause requires judgment and experience. The experts at HRST have the knowledge and understanding of boiler design and operation needed to resolve boiler problems such as tube failures, casing cracks, circulation problems, steam purity, burner distribution problems, performance shortfall, and control problems.
PDF Brochure: Root Cause Analysis
HRSG Cycling Assessment – We can help improve cycling techniques to reduce the risk of problems. This is accomplished by an on-site visit by an HRST engineer to review procedures and problem history, review control room data, view piping configuration, and interview operators. The information gathered is then used to recommend improvements to avoid or reduce cycling related problems. This approach can bring considerable benefit at a minimal cost since many HRSGs were not originally specified or designed to cycle.
Above Left: section-by-section performance analysis results. Above Right: test thermocouple installation on desuperheater pipe for performance evaluation.
Below: Test thermocouple monitoring for LP Economizer failure investgation and graph of results indicating problems.
