We utilize our design, performance modeling and stress analysis experience to work on a variety of different analysis projects specific to your HRSG or boiler. The combination of our field inspection experience and engineering skills are crucial ingredients for a successful analysis project.

Performance Evaluation

HRST developed a method to best fit performance data and allows efficient identification of bad data. 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.

FAC 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. 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 optimize 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. Our FAC Risk Assessment works best in conjunction with our FAC UT Monitoring program.

HRSG Cycling Assessment

Improving cycling techniques reduces 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 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. This includes HRSG low load operation and the challenges of high desuperheater spray water flows at low loads. Our assessment will evaluate the limitations of the existing design and options for improvements.

Finite Element Analysis (FEA)

Fatigue and other forms of thermal and stress related failures are common in HRSGs. HRST provides structural analysis on HRSG components to determine effects of fatigue, thermal stress and other related phenomena. FEA is also useful as we design new products to address recurrent issues in the industry.

Root Cause Failure Analysis (RCFA)

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.

Computational Fluid Dynamics (CFD) Analysis

Gas side flow simulation is crucial to understand the performance of critical HRSG components such as duct burners, perforated plates and inlet guide vanes. HRST provides flow simulation solutions to determine the effectiveness of flow devices by using cutting edge CFD solvers such as ANSYS CFX.

Layup Guidance

HRST provides layup guidance based on site-specific conditions and client needs.

Gas Turbine Upgrade Thermal Analysis

We efficiently and accurately create a thermal performance model to assess the impacts of combustion turbine exhaust changes on overall HRSG performance.

Deposit Analysis

Internal tube deposits can lead to tube failures. HRST determines the best location to take tube samples. Then we analyze the samples and recommend the appropriate follow up action.