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ANALYSIS
Analysis
HRST delivers a comprehensive suite of analytical, diagnostic, and engineering services designed to improve HRSG and boiler performance, mitigate operational risks, and extend equipment life. These solutions combine advanced modeling tools, field expertise, and proven engineering practices to help plant owners make smart, data‑driven decisions.
The combination of our field inspection experience and engineering skills are crucial ingredients for a successful analysis project.
Interested in learning more? Click here to request our Analysis and Engineering Solutions digital booklet.
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 Condition assessment
Worried about the future of your equipment? HRST’s HRSG Condition Assessment will help. In a Condition Assessment we consider plant history, HRSG design, and operating data to confirm failure mechanisms and design issues, and reveal historical failure trends.
plant water chemistry review
HRST provides expert analysis of your water chemistry program and delivers recommendations to get your chemistry program started or back on track. HRST’s Plant Water Chemsitry Review includes instrument evaluation and data review & analysis.
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
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.
Not sure where to take samples? Ask us about borescope inspections.
hp drum critical crack size assessment
HRSG cycling and original fabrication quality problems combine to create pressure part weld cracks. Avoid unplanned repairs with pre-outage critical crack size analysis. HRST will determine if a weld crack size warrants immediate repair, or if the cracks can remain in operation with future re-inspection.
Drain system modification
Cycling operations place significant demands on HRSG drain systems. Without proper design, these systems can suffer from increased stress and operational inefficiencies. HRST can improve drainpipe routing, enchance control systems, and optimize drainpipe sizing.
cps risk assessment
HRST’s analysis identifies and ranks high-risk areas for NDE, incorporating inspection results, operating history, and piping design reviews. This process evaluates degradation mechanisms such as creep, fatigue, and corrosion, providing a ranked list of critical locations for targeted NDE.