Professional Documents
Culture Documents
Diagnostic - Troubleshooting HRSG
Diagnostic - Troubleshooting HRSG
Diagnostic - Troubleshooting HRSG
SED
R I
A L
LICE
M AT E
WARNING:
Please read the License Agreement
on the back cover before removing
the Wrapping Material.
Effective December 6, 2006, this report has been made publicly available in
accordance with Section 734.3(b)(3) and published in accordance with Section
734.7 of the U.S. Export Administration Regulations. As a result of this
publication, this report is subject to only copyright protection and does not
require any license agreement from EPRI. This notice supersedes the export
control restrictions and any proprietary licensed material notices embedded in
the document prior to publication.
Technical Report
Diagnostic/Troubleshooting
Monitoring to Identify Damaging
Cycle Chemistry or Thermal
Transients in Heat Recovery Steam
Generator Pressure Parts
1008088
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
ORDERING INFORMATION
Requests for copies of this report should be directed to EPRI Orders and Conferences, 1355 Willow
Way, Suite 278, Concord, CA 94520, (800) 313-3774, press 2 or internally x5379, (925) 609-9169,
(925) 609-1310 (fax).
Electric Power Research Institute and EPRI are registered service marks of the Electric Power
Research Institute, Inc.
Copyright 2005 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS
This report was prepared by
EPRI
3412 Hillview Avenue
Palo Alto, CA 94304
Principal Investigator
R. B. Dooley
Aptech Engineering Services, Inc.
1253 Reamwood Avenue
Sunnyvale, CA 94089
Principal Investigator
S. Paterson
J. Michael Pearson & Associates Co. Ltd.
9 Abbit Crescent, RR1
Georgetown, Ontario
Canada L7G4S4
Principal Investigator
M. Pearson
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Diagnostic/Troubleshooting Monitoring to Identify Damaging Cycle Chemistry or Thermal
Transients in Heat Recovery Steam Generator Pressure Parts, EPRI, Palo Alto, CA: 2005.
1008088.
iii
PRODUCT DESCRIPTION
The worldwide fleet of combined cycle units with heat recovery steam generators (HRSG) has
exhibited a disappointing track record with respect to reliability and availability in terms of
HRSG Tube Failures (HTF). This report will assist operators in identifying the harmful chemical
and thermal transient excursions that lead to failure.
Results & Findings
The report provides a series of road maps to identify, measure, evaluate, correct, and control
those cycle chemistry and thermal transients that result in poor HRSG reliability within the
design life of a generator. Particular emphasis has been given to eliminating failures in the first
few years of operation. The appendices of the report include background information on tube
temperature measurement, cycle chemistry monitoring, and estimates of cost.
Challenges & Objectives
The most frequently occurring HTF damage mechanisms include thermal and corrosion fatigue,
thermal quench cracking, flow-accelerated corrosion, and under deposit corrosion. These are
either influenced by transiently high, thermally induced cyclic stresses or inadequate feedwater
and evaporator chemistries. On the chemistry side, it is clear that the chemistries adopted during
the design phase of a plant set the stage for later failures. The objective of this work was to
develop a comprehensive approach that will identify and eliminate non-optimum cycle
chemistries and avoid potentially damaging thermal transients in the various HRSG circuits as
early in life as possible.
Applications, Values & Use
Organizations that apply the monitoring and diagnostic approaches delineated in this report can
operate HRSGs with added confidence that chemical and thermal effects have been identified
and will not lead to HTF damage and failure. Adoption of the necessary practices will put an
organizations HRSG on the road to world-class performance.
EPRI Perspective
To address the suite of issues related to HTF, EPRI has developed a series of documents: HRSG
Cycle Chemistry Guidelines (EPRI report TR-110051), HRSG Tube Failure Manual (EPRI
report 1004503), and Delivering High Reliability HRSGs (EPRI report 1004240). However,
these documents by themselves would not lead to a reduction in repeat HTF because many of the
influencing features leading to failure were an integral part of the original specification and
design aspects or resulted from inadequate commissioning. Organizations needed an approach to
recognize these deficiencies in the early life of an HRSG. The current document provides this
methodology. The next steps are to conduct a number of case studies to illustrate the efficacy of
the approach.
Approach
The EPRI team first developed an interim White Paper on the topic. This document was used to
solicit host HRSGs. The team worked with one host site, reviewed its chemistry and possible
thermal transients, and made suggestions for installation of thermocouples and for cycle
chemistry monitoring. Based on this exercise, the team upgraded the white paper to the current
report.
Keywords
Heat recovery steam generator (HRSG)
Combined cycle units
Tube failures
Thermal transients
Cycle chemistry
Monitoring and diagnostics
vi
ABSTRACT
To identify the root causes of the leading HRSG Tube Failure (HTF) mechanisms, and to
identify damage accumulating from non-optimum cycle chemistry and severe thermal transients,
it is necessary to conduct diagnostic monitoring. This report, which is within a series of EPRI
reports, provides details and case studies of how to conduct monitoring of HRSG tubing and
header/tubing attachments. A road map approach is provided with numerous examples.
vii
ACKNOWLEDGMENTS
The authors of this report
R. B. Dooley, EPRI
S. Paterson, Aptech Engineering Services, Inc.
M. Pearson, J. Michael Pearson & Associates Co. Ltd.
acknowledge the contributions from the following individuals:
Kevin Shields, EPRI
Kurt Koenig, Plant Engineer, Jasper Plant, SCE&G
Steve Palmer, Plant Manager, Jasper Plant, SCE&G
John Pearrow, Manager System Chemistry, Jasper Plant, SCE&G
Galen Bullock, Maintenance Superintendent, Jasper Plants, SCE&G
ix
CONTENTS
1 INTRODUCTION....................................................................................................... 1-1
1.1 Background....................................................................................................... 1-1
2 STEPS FOR THE IDENTIFICATION, CORRECTION AND CONTROL OF
CYCLE CHEMISTRY OR THERMAL TRANSIENT INFLUENCED HRSG
PRESSURE PART DAMAGE...................................................................................... 2-1
2.1 Introduction to Road Map Steps........................................................................ 2-1
2.2 Step 1: Review of Unit Design, Operational and Maintenance Information....... 2-2
2.2.1 Cycle Chemistry Review ............................................................................ 2-2
2.2.2 Review of Pre-operational and Layup Practices ...................................... 2-11
2.2.3 Review of Thermal-Mechanical Parameters ............................................ 2-12
2.3 Step 2: Identifying the Potential Cycle Chemistry or Thermal-Mechanically
Influenced Damage Mechanisms........................................................................... 2-15
2.4 Step 3: Specify the Type and Locations for the Diagnostic Instrumentation ... 2-16
2.5 Step 4: Install High Priority Diagnostic Instrumentation .................................. 2-29
2.6 Step 5: Operate Unit over a Wide Range of Operating Conditions ................. 2-30
2.7 Step 6: Review and Evaluate the Results of Diagnostic Instrumentation
Measurements ....................................................................................................... 2-31
2.8 Step 7: Evaluate, Engineer and Implement Operational, Maintenance and
Design Enhancements to Ameliorate or Eliminate Damage Influencing Cycle
Chemistry or Thermal-Mechanical Events ............................................................. 2-33
2.9 Step 8: Verify the Success of the Changes through Additional Monitoring
and Evaluation ....................................................................................................... 2-34
2.10 Step 9: Ongoing Monitoring, Evaluation, and Improvements ........................ 2-34
3 REFERENCES.......................................................................................................... 3-1
A BACKGROUND INFORMATION REVIEW ............................................................. A-1
General Plant/Unit Information.................................................................................A-1
xi
xii
LIST OF FIGURES
Figure 1-1 Cycle chemistry evaluation, and improvement road map: feedwater (all1
ferrous cycles) ...................................................................................................................1-5
1
Figure 1-2 Cycle chemistry evaluation, and improvement road map: evaporator water ...........1-6
Figure 1-3 Thermal transient evaluation and optimization road map .........................................1-7
Figure 2-1 Example generic cycle chemistry diagram for a triple pressure HRSG with
reheat .................................................................................................................................2-4
Figure 2-2 Cycle chemistry diagram showing the chemical feed and chemistry
monitoring locations in a triple pressure HRSG with reheat that is controlled with
ammonia additions in the feedwater and trisodium phosphate additions to the IP
and HP drums. ...................................................................................................................2-5
Figure 2-3 Total (particulate + soluble) iron levels measured in each of three HRSGs
after a few months of plant operation. Note that the iron concentrations are close to
the desired value of less than 5 ppb for all the sections of the cycle except the
intermediate pressure drums. ..........................................................................................2-11
Figure 2-4 Characterization of an aggressive basic thermal shutdown and startup cycle. ......2-15
Figure 2-5 Example of a preliminary 21 day in-situ test to confirm that reducing the
injection of hydrazine does reduce the total level of iron in the feedwater.
Subsequently on this unit, the reducing agent was eliminated.........................................2-17
Figure 2-6 Example arrangement of a set of thirteen diagnostic/ troubleshooting
thermocouples that identified and quantified the magnitude of cold startup related
row-to-row and element-to- element tube temperature differences in an HRSG
reheater bundle. Prior to introducing steam flow (at approximately 38 minutes after
combustion turbine startup) the leading row tubes (Row A) were approximately
o
o
55 C (100 F) hotter than the trailing, Row B tubes. After introducing steam flow, two
of the leading row tubes near the right hand side of the bundle were rapidly
quenched to near the estimated saturation temperature. This forward flow of
saturated liquid (most likely undrained condensate) resulted in a tube to tube
o
o
temperature difference near 140 C (250 F). In more recent tests on another design
o
o
of HRSG tube-to-tube temperature differences in excess of 167 C (300 F) were
recorded. ..........................................................................................................................2-24
Figure 2-7 Example of the location of twenty eight diagnostic/ troubleshooting
thermocouples installed in a vertical tube high pressure economizer tube bundle. .........2-26
Figure 2-8 Seven high pressure economizer tube Row A (just beneath the outlet
header, see Figure 2-7) thermocouples measurements during a cold start. At this
location the measurements suggest that the HP economizer approach temperature
o
o
is at least 10 F (6 C) and the tube to tube temperature differences are less than
o
o
25 F (14 C). No steaming or severe tube to tube temperature differences would be
indicated from these thermocouples. ...............................................................................2-27
xiii
Figure 2-9 Seven high pressure economizer tube Row B (just after the final upper
return bend, see Figure 2-7) thermocouples measurements during a cold start. At
this location the measurements indicate that the water in four of the seven tubes is
o
o
more than 25 F (14 C) above the estimated saturation temperature (i.e., air-locking
or steaming is occurring in the tubes near the edges of the bundle). This resulted in
o
o
a tube to tube temperature difference near 80 F (44 C)...................................................2-27
Figure 2-10 Seven high pressure economizer tube Row C (just after the first upper
return bend, see Figure 2-7) thermocouples measurements during a cold start. At
this location the measurements indicate that the water in one of the seven tubes is
o
o
more than 10 F (6 C) above the estimated saturation temperature (i.e., air-locking
or steaming is occurring in at C23). Since the water in the other tubes is more than
o
o
100 F (55 C) below the saturation temperature this results in a tube to tube
o
o
temperature difference that is greater than 100 F (55 C). ................................................2-28
Figure 2-11 Seven high pressure economizer tube Row D (in the vertical downflow
tube just beneath the inlet header, see Figure 2-7) thermocouples measurements
during a cold start. At this location the measurements indicate that the water in the
three cooler tubes, which are probably representative of the majority of tubes in the
row, remains close to the HP economizer feedwater inlet temperature, whereas the
fluid in the other tubes with TCs (that are close to the blind ends of the inlet header
o
o
and further from the inlet pipes on the header) operate up to 67 C (120 F) hotter
than the coldest tubes due to either flow stagnation or reverse, recirculating flow
upwards in the tubes with the lowest pressure drop between the upper inlet and
lower return header. Lower flow and high temperatures in the tubes furthest from
the inlet pipes were caused by higher hydraulic resistance and buoyancy forces in
the water in these tubes. Gas laning and elevated heat absorption in the tube
circuits near the sides of the bundle may have been partially responsible for the
increased buoyancy forces, reduced flow and elevated water temperature
observed. .........................................................................................................................2-29
Figure 2-12 Time line plot of the bulk temperatures measured up and downstream of a
single parallel pass, two row, vertical tube, finishing (high temperature) reheater
4
during a warm start made with a low hot reheat steam temperature setpoint . Two
significant temperature drops were observed. The first occurred soon after steam
flow was established through the reheater bundles and was attributed to forward
flow of undrained condensate. The second event was more severe and was caused
by overspraying of the interstage attemperator too close to saturation temperature.
Operating practices that contributed to the overspraying were substantial lowering
of the RH steam outlet temperature setpoint and excessively aggressive ramping of
the CT load and exhaust gas temperature to the maximum gas temperature.
Simultaneous raising of HP pressure exacerbated the severity of the event. ..................2-32
Figure 2-13 Spatial temperature plot of 74 reheater tube thermocouples. This time slice
was associated with the attemperator overspray event shown in Figure 2-12. Some
o
o
tubes were more than 83 C (150 F) hotter than the adjacent tubes. The tubes near
the inlet nozzle centered above tube element #9 were severely cooled in both tube
rows. Near the other inlet nozzles the dogleg tube row (Row #2) was being cooled
well below the straight, leading row of tubing...................................................................2-33
Figure B-1 Location of thirty two thermcouples to be installed in direct contact with the
tube OD surface between the finned tubing and the headers ........................................... B-8
Figure B-2 Location of fourteen thermocouples to be installed in direct contact with the
tube OD surface between the finned tubing and the headers ........................................... B-9
xiv
Figure B-3 Location of eighteen thermocouples to be installed in direct contact with the
tube OD surface between the finned tubing and the headers ......................................... B-10
Figure B-4 Location of three thermocouples to be installed in direct contact with the OD
surface of the downcomer on the east tube bundle ........................................................ B-11
Figure B-5 Location of fifteen thermocouples to be installed in Bundle A in direct contact
with the tube OD surface between the finned tubing at three locations on 5 tube
elements.......................................................................................................................... B-12
Figure C-1 Removal of a window of lagging and insulation on an HP downcomer.................. C-4
Figure C-2 Removal of surface oxide with gentle grinding ...................................................... C-5
Figure C-3 Preheating of cleaned surface and verification of the surface temperature
with a Tempil stick............................................................................................................. C-6
Figure C-4 Attachment of the work lead (attached with a magnet) and the electrode lead
(thermocouple wire held on the surface with a plier which is electrically connected
to the capacitance discharge power supply. ..................................................................... C-7
Figure C-5 Completed thermocouple junction welds ............................................................... C-8
Figure C-6 Supporting and guiding the thermocouple wire from the thermocouple
junction to the data acquisition system. It is important that the wire is guided in a
manner that provides for thermal expansion and protection from personnel. ................... C-9
Figure C-7 Insulation covering the thermocouple junctions on a HPSH tube. The
insulation used was spare manway door insulation that was held in place with two
wraps of stainless steel wire. .......................................................................................... C-10
Figure C-8 Mock-up T91 tube that was used to qualify the thermocouple junction
welding procedure. Note the two unsuccessful welds above the completed welds.
Unsuccessful weld junctions should be removed by light grinding.................................. C-11
Figure C-9 Polished metallurgical cross-section of one of the mock-up thermocouple
junctions. Although this junction has some minor porosity, undercut and incomplete
fusion it will provide accurate temperature readings and will probably have
adequate reliability. ......................................................................................................... C-11
Figure C-10 Cross-section through another thermocouple junction. This junction has
severe porosity and small cracks (see Figure C-11). This thermocouple junction will
provide accurate temperature readings but is not adequate if longevity and
resistance to in-service cracking are important. .............................................................. C-12
Figure C-11 Close-up of the thermocouple junction shown in Figure C-10. Note the
severe porosity, and cracks that extend toward the tube surface. The tube surface
beneath the weld will have a shallow, but very hard heat affected zone. The
combination of porosity, microcracks, and the hard base metal heat affected zone
could lead to cracking. .................................................................................................... C-12
xv
LIST OF TABLES
Table 2-1 Example of Measured or Recommended Cycle Chemistry Parameters for a
Triple Pressure HRSG with Reheat Treated with Ammonia in the Feedwater and
Trisodium Phosphate in the IP and HP Drums. Selected measured values
measured at full load are shown in the right-hand column. (The values within this
table are not all in line with the EPRI Guideline values and should not be applied to
1
the readers unit. Please see the EPRI Guidelines ) ...........................................................2-6
Table 2-2 HRSG Cycle Chemistry Monitoring Parameters ......................................................2-18
Table 2-3 HRSG Thermal-Hydraulic Monitoring Parameters...................................................2-21
Table A-1 DCS Attribute Grouping Useful for Identifying and Characterizing ThermalMechanical Cycles ............................................................................................................ A-3
Table B-1 Location and Number of Diagnostic Thermocouples .............................................. B-7
xvii
1
INTRODUCTION
1.1 Background
There have been numerous heat recovery steam generator (HRSG) pressure part failures that
have resulted from less than optimal cycle chemistry and damaging thermal transients. It is
estimated that poor cycle chemistry and damaging thermal transients are responsible for more
than 80% of the pressure part failures that have been experienced in HRSGs.
To address this concern EPRI developed the Interim HRSG Cycle Chemistry Guidelines1. These
guidelines provided road map approaches to the monitoring, optimization, and control of cycle
chemistry in single-, double- and triple-pressure combined cycle HRSGs. Next EPRI prepared
the HRSG Tube Failure (HTF) Manual2. This manual identified all the current HTF and ways of
preventing repeat failures. EPRI then recognized that there was a need for a more proactive
approach to prevention of HRSG pressure part damage. A report entitled Delivering High
Reliability Heat Recovery Steam Generators3 was prepared. This document presented needed
actions during the design, commissioning, and operation phases, etc. to prevent HRSG pressure
part damage and failures.
This latter effort, and recognition that pressure part failures caused by transiently high, thermally
induced cyclic stresses are becoming increasingly frequent, led to the need to compile
information on the world wide design codes dealing with fatigue and their deficiencies, and thus
the need to provide better guidance for the assessment of creep fatigue in components that
normally operate at higher temperatures, thermal fatigue in lower temperature components or
corrosion fatigue of HRSG pressure parts. It also led on the chemistry side to the clear
understanding that many of the chemistries adopted during the design phase are designed to fail.
Historically, poor commissioning practices have generally failed to identify or evaluate the
damaging consequences of either the thermal transients or the non-optimum chemistry. This
report provides a road map approach for identifying non-optimum chemistry regimes and
damaging thermal transients in the various circuits.
The most frequently occurring HRSG tube failure (HTF) damage mechanisms include:
1. Corrosion fatigue
2. Flow accelerated corrosion, single and two-phase
3. Underdeposit corrosion (hydrogen damage, acid phosphate corrosion, caustic gouging)
4. Pitting corrosion
5. Thermal quench-induced fracture
1-1
6. Thermal fatigue
7. Creep fatigue
Damage mechanisms 2, 3 and 4 are predominately cycle chemistry influenced and mechanisms
5, 6 and 7 are thermal mechanical mechanisms. Damage mechanism 1 requires the simultaneous
occurrence of a corrosive environment and high thermally induced stresses.
Some common root cause factors for the cycle chemistry influenced failures include:
a) Initiating startup operation with a corrosive environment in the water, increasing the risk of
corrosion fatigue damage.
Deficient design that incorporates features and details that develop high localized thermal
stresses in pressure parts.
c) Operation with a corrosive environment beneath waterside deposits, increasing the risk of
underdeposit corrosion mechanisms including hydrogen damage (HD), acid phosphate
corrosion (APC) and caustic gouging (CG).
1-2
Carryover of sodium sulfate and deposition in reheaters (rare in HRSGs because of the
low number of units with condensate polishers).
Some common root cause factors for the thermally induced failures include:
a) In horizontal gas path HRSGs, transient tube-to-tube temperature variations in vertical tubes
connected to common upper and lower headers. These temperature differences are intended
to be very small. Typically well under 50oC (90oF). Tube-to-tube temperature differences
above 100oC (180oF) have been measured in numerous HRSGs. There are a variety of root
causes of these unanticipated and damaging temperature differences including:
Startup conditions with gas temperatures and flows that are excessive.
Forward flow of undrained condensate in HPSH or RHs during startups due to poor
design and/or arrangement of lower connecting pipes and the drains removal and disposal
systems or to incorrect operation.
Introduction of hot recirculation water into the cool inlet of the LP preheater following
trips or shutdowns.
Steaming or air lock in some economizer tubes due to lack of or inadequate venting.
Periodic reverse or stagnant flow of feedwater in some economizer tubes during startups
or continuous flow recirculation on load.
b) Tube-to-header or through wall header temperature gradients must also be controlled to avoid
localized yielding and cyclic damage. Localized permanent cyclic damage may occur when
these gradients exceed a critical value that is dependent on the local geometry. These
damaging transients are caused by:
Excessively fast steam temperature and/or steam pressure increases during startups.
1-4
Figure 1-1
Cycle chemistry evaluation, and improvement road map: feedwater (all-ferrous cycles)1
1-5
Figure 1-2
Cycle chemistry evaluation, and improvement road map: evaporator water1
1-6
Figure 1-3
Thermal transient evaluation and optimization road map
1-7
2
STEPS FOR THE IDENTIFICATION, CORRECTION AND
CONTROL OF CYCLE CHEMISTRY OR THERMAL
TRANSIENT INFLUENCED HRSG PRESSURE PART
DAMAGE
2-1
Next the results of recent full load grab sample and on-line monitoring results should be
reviewed (e.g., Table 2-1 and Figure 2-3) to see what attributes are measured, what control or
action limits have been set and which parameters have been outside the optimum ranges. Using
this approach it is always possible to quickly identify non-optimal conditions that should be
corrected prior to any further operational transient studies. For example, although comprehensive
2-2
chemistry results were not available, the available measurements listed in Table 2-1 and Figure
2-3 identified the following issues:
The makeup and preheater inlet water have excessive conductivity and dissolved oxygen
contents.
Based on these findings a more thorough investigation to determine the source of the high
conductivity and oxygen readings in the makeup and turbine condenser condensate water would
be performed, starting with independent measurements and instrument calibration or more
frequent and comprehensive grab sample analyses. Measurements of air inleakage would also be
made.
Ongoing IP drum water iron monitoring including some detailed monitoring performed during
thermal transients and following IP drum blowdown would be performed to attempt to
understand the reason for the elevated levels of iron in the IP evaporator.
The elevated conductivity and phosphate instabilities in the IP and HP evaporator water would
be investigated by checking the calibration of the instruments, and monitoring sodium,
phosphate, pH and cation conductivity and iron more frequently and over a range of operating
conditions. If further evidence of phosphate hideout was found then an internal videoprobe
examination of the leading row of HP and IP evaporator tubing would be performed. If waterside
deposits were observed then instrumentation to measure the gas temperature profile, circulation
ratios, and steam quality at various fired and unfired operating conditions in the HP and IP
evaporators would be performed. This detailed monitoring might include adding gas and midwall
chordal thermocouples into sections of the leading row tubing experiencing deposition. To
determine if the circulation and steam quality are acceptable may require installing flow meters
on each of the downcomers and a few selected riser tubes and pressure gages and thermocouples
on the top and bottom of the downcomers and deposition prone riser tubes.
2-3
Figure 2-1
Example generic cycle chemistry diagram for a triple pressure HRSG with reheat
2-4
Figure 2-2
Cycle chemistry diagram showing the chemical feed and chemistry monitoring locations
in a triple-pressure HRSG with reheat that is controlled with ammonia additions in the
feedwater and trisodium phosphate additions to the IP and HP drums.
2-5
Sample
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
>1
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
20
25
Immediate
shutdown
Measured
full load
values
*
*
2-6
10
0.1
15
>0.2
0.50 to
1.02
7.1 to 8.1
0
300
>0
0.20
0.35
0.65
20
40
> 40
10
20
> 0.65
0.40 to
0.84
69 to 78
> 20
Location/
Parameter
Sample
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
Total organic
carbon, ppb
Iron, ppb
Weekly or
Troubleshooting
Weekly or
Troubleshooting
200
> 200
>5
Continuous
0.20
0.35
0.65
20
40
> 40
Preheater
inlet water
Cation
conductivity,
S/cm
Dissolved
oxygen, ppb
(if not
measured at
CPD)
Ammonia
pH
Continuous
Iron, ppm
Weekly
Sodium, ppb
ORP, mV
Troubleshooting
Specific conductivity, S/cm
Total organic Troubleshooting
carbon, ppb
Hardness
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
Immediate
shutdown
Measured
full load
values
3 to 5
> 0.65
10
> 20
4.6 to 6.0
200
> 200
LP drum water effluent (IP and HP economizer and attemperator water influent)
Cation
Continuous
> 0.65
0.20 0.35
0.65
conductivity,
S/cm
Dissolved
Once per shift
1 to 10 15
> 20
20
oxygen, ppb
(if not
measured at
CPD)
pH
Continuous
9.8 to
< 9.8 or > 10.2
< 8.5 or
10.2
>12
Silica, ppb
> 20
10
15
20
Iron, ppb
Weekly
>5
5
0.27 to
0.62
96 to 103
9.8 to 9.9
4 to 7
2-7
Sample
*
*
Troubleshooting
Continuous
Once per day
Weekly
*
*
Continuous
Once per day
Weekly
2-8
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
Immediate
shutdown
Measured
full load
values
2.8 to 4.3
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
5
Consistent with pH, no limit
Copper, ppb
Ammonia,
ppm
Chlorides,
ppb
ORP, mV
Normal
To + 50
< 1 or > 4
9.2 to 9.6
0.6
5
6
15
0.1 to 4.1
< 9.2
< 8.5 or
>12
>0.6
>5
9.2 to
10.0
7 to 23
1.3 to
17.6
3
< 1 or > 4
9.2 to 9.6
5
6
15
0.1 to 3.8
< 8.5 or
>12
>0.6
>5
9.4
3 to 7
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
LP drum
saturated
steam
Cation
conductivity,
S/cm
Sodium, ppm
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
Silica, ppb
10
20
9.2 to 9.6
40
> 40
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
10
20
9.2 to 9.6
40
> 40
Location/
Parameter
Immediate
shutdown
Measured
full load
values
ppm
pH
IP drum
saturated
steam
Cation
conductivity,
S/cm
Sodium, ppm
Silica, ppb
pH
10.2
9.8 to
10.0
HP drum
saturated
steam
Cation
conductivity,
S/cm
Sodium, ppm
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
Silica, ppb
10
20
40
> 40
0.55
1.0
> 1.0
pH
9.2 to 9.6
0.30
0.29 to
0.35
3.3 to
10.7
9.7 to
10.0
2-9
Location/
Parameter
Sample
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
Sodium, ppm
Continuous
10
20
> 20
Silica, ppb
10
20
9.2 to 9.6
40
> 40
0.30
0.55
1.0
> 1.0
10
20
> 20
10
20
9.2 to 9.6
40
> 40
pH
pH
0.30
0.55
1.0
> 1.0
10
20
> 20
Silica, ppb
pH
10
20
9.2 to 9.6
40
> 40
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
10
20
9.2 to 9.6
40
> 40
Reheat
outlet steam
Cation
conductivity,
S/cm
Sodium, ppm
Silica, ppb
pH
Notes:
2-10
Immediate
shutdown
Measured
full load
values
0.11 to
0.15
0.12
30
25
20
15
10
IP
#3
H
PE
co
n#
H
1
PE
co
n#
H
2
PE
co
n#
3
H
P#
1
H
P#
2
H
P#
3
IP
#2
IP
#1
LP
#3
LP
#2
on
de
ns
at
e
LP
#1
Figure 2-3
Total (particulate + soluble) iron levels measured in each of three HRSGs after a few
months of plant operation. Note that the iron concentrations are close to the desired value
of less than 5 ppb for all the sections of the cycle except the intermediate pressure drums.
surfaces. Under alternating on-line oxidizing and off line reducing conditions the protective iron
oxides will become non-adherent and during restarts very high concentrations of oxide will
release from the water touched surfaces, flow forward and deposit in the high heat flux sections
of the IP and HP evaporators.
One of the goals of the cycle chemistry program, especially for units that are required to stop and
start frequently should be to condition the water in a way that makes the pH fluctuate as little as
possible and maintains the oxidation-reduction potential (ORP) either positive (oxidizing) or
negative (reducing). If the on-line chemistry requires a reducing (negative) ORP then the off-line
wet layup should also be designed to produce water that is reducing. On the other hand, if the
more desirable practice (for most modern, all-ferrous pressure part HRSGs) of treating the
feedwater with chemicals that produce a positive ORP is used then the wet layup practices
should be designed to produce water that also maintains a positive ORP. The practices to
accomplish these objectives are documented in the EPRI Interim Cycle Chemistry Guidelines1.
EPRI is currently working on a HRSG layup guideline which will provide an update on the best
options for wet and dry layups.
For units that dont use a feedwater reducing agent except for wet layups the feedwater and LP,
IP and HP drum water iron concentrations should be measured during some cold starts that were
preceded by wet layup and starts following extended weekend shutdowns. Grab samples taken
every 15 minutes during the startup will provide a baseline for comparison tests performed using
wet layups that only use a properly applied nitrogen blanket and cycle chemistry that is the same
as the operating chemistry.
This review should also include a detailed evaluation of the nitrogen capping feedpoints, and
practices. A common error is to provide the nitrogen too late (after some air entered the pressure
parts). It is important that the nitrogen cap be added to the main condenser and turbine, deaerator
and storage tank and steam drums while there is still residual heat and pressure present. This
positive pressure of nitrogen must also be maintained throughout the layup period. For wet layup
that last longer than a few days the water in evaporator and economizer circuits may need to be
circulated to avoid prolonged stagnant conditions.
With regard to diagnostic monitoring issues and wet layups some consideration should be given
to instrumentation requirements and sampling intervals to ensure that the pH and oxygen levels
in the economizer, evaporator, condenser and feedwater water are maintained within acceptable
levels. If dry layups are being used then instrumentation requirements for monitoring the
humidity throughout the HRSG, turbine, condenser and feedwater system should be addressed.
2.2.3 Review of Thermal-Mechanical Parameters
The thermal mechanical design and operating practices review can begin in a fashion that is
similar to the cycle chemistry review but usually requires considerably more information and
previous experience analyzing the results from diagnostic monitoring of other HRSGs because
many of the key damage influencing operating targets and control limits are often not known and
the damaging thermal events can be very localized and of short duration.
2-12
The review of steady state operating parameters at full load and at part loads at the lower end of
the normal operating range might occasionally provide some indication of problems in HP
superheater or reheater. However, even when bulk values of economizer approach temperature or
evaporator pinch points are within their expected ranges the unit may still be experiencing
severe, damaging thermal transients because the tube temperature anomalies usually do not cause
discernible deviations in the bulk outlet fluid temperature measurements.
The next step is to review the transient conditions for a broad sampling of shutdowns and
startups. Unless the unit already has definitions for different transients the following definitions
could be used:
Rapid hot restarts - with the unit offline for less than ~ 5 hours
Hot starts made after longer shutdowns where the HP drum pressure prior to the startup
remains above approximately 35 barg (500 psig). These are associated with shutdowns that
are around 5 to 12 hrs, depending on the method used for the shutdown and the leak tightness
of the HP section of the HRSG.
Warm starts made after the HP drum pressure prior to the startup is between approximately 7
barg (100 psig) to 35 barg (500 psig) , provided the unit was boxed up after the shutdown
with high HP drum pressure and is leak tight. These are associated with weekend shutdowns.
Some units will not be able to maintain HP drum pressure above 7 barg (100 psig) for more
than approximately 12 hrs to 24 hrs offline.
Extended warm starts made after the HP drum pressure has approached ambient conditions
(0.5 barg to 7 barg, 7 psig to 100 psig). These are typical of long weekend shutdowns 24 to
60 hours although some units may experience HP drum pressure decay to ambient pressure in
30 hours or less offline. Although rare, some units are able to maintain pressure above
ambient for time periods approaching 72 hrs or more.
Cool starts made from 0 barg (0 psig) pressure, but where the HP drum water temperature
remains above about 75oC (167oF).
Cold starts made after the HP drum water are close to ambient conditions.
Unless a stop/start algorithm has been programmed into the plant historian it will probably only
be practical to review a small number of recent shutdown and startup events.
If the plant historian does not have a software algorithm to identify the date, time, type and
relative severity of the stop/start transient then plots of the following parameters can be used to
quickly identify the beginning and ending date/time of specific shutdowns and startups:
HP drum pressure
2-13
The basic thermal cycle comprises a CT/HRSG shutdown, followed by a period of natural
cooling while offload, followed by the CT/HRSG startup and reloading to high load, followed by
the high temperature dwell part of the cycle during operation on load. The beginning of this
thermal cycle is identified by the beginning of combustion turbine load decrease from the highest
operating load. The beginning of the start is identified by the purge conditions (the combustion
turbine speed increases with no load or increase in exhaust gas temperature). The end of the
startup is when the combustion turbine reaches stable load with the HRSG producing steam at
maximum temperature and pressure.
The category of start for the HRSG is determined by the HP drum pressure just prior to the
startup. Figure 2-4 illustrates the constituent parts of one basic thermal cycle. The procedures
used in Figure 2-4 for both the shutdown and startups parts of the cycle are aggressive and
conflict with those recommended in Section 4.3 of Reference 3 and are likely to lead to
premature damage or failure in critical parts of the HRSG if cycled.
Once the time periods of the shutdown and startup phases of a range of thermal cycles have been
identified then more detailed data plots and evaluations for each of these time periods should be
performed. Appendix A list various DCS data attributes that have been found to provide useful
insights into the potential for specific types of thermal-mechanical damage. The reader is
encouraged to start by identifying a pressure part and design feature of concern then identify the
available DCS instrumentation attributes that provide insight about the thermal-mechanical loads
associated with the pressure part feature. Appendix A provides examples of timeline plot
attributes that have been useful for specific components/features.
2-14
HP drum pressure
CT exhaust temp
CT load
200
CT speed
180
160
Shutdown
(1) No controlled cooling (CT speed = 0)
(2) Pressure decay rate (~-1 psi/min)
1400
140
1200
120
1000
100
800
80
Min. HP drum pressure 350 psig
600
60
400
40
200
1600
1800
20
Purge
1440
1320
1200
1080
Time, minutes
960
840
720
600
480
360
240
120
0
0
Figure 2-4
Characterization of an aggressive basic thermal shutdown and startup cycle.
The procedures used for this shutdown are not recommended for units intended for
cycling service. Note that the shutdown was performed with rapid deloading and
shutdown of the combustion turbine (before the superheater headers had been gently
cooled close to the saturation temperature). Next is seen a natural cooling and pressure
decay of the HP drum. This is followed by a short purge signifying the commencement of
the startup (identified by increased combustion turbine speed with a slight decrease in
combustion turbine exhaust temperature and decay in drum pressure) and an
approximately 1-1/2 hr restart. The HP drum pressure decay to approximately 350 psig
(saturation temperature 224oC (435oF)) is within the range characterized as a warm start.
2.3 Step 2: Identifying the Potential Cycle Chemistry or ThermalMechanically Influenced Damage Mechanisms
After completion of the initial review, good engineering judgment is also needed to assess the
potential for damaging thermal-mechanical transients that may not be picked up with existing
instrumentation. Appendix B provides an example of an engineering judgment based preliminary
assessment of a triple pressure, horizontal gas path HRSG with reheat. These judgment based
assessments rely heavily on knowledge and the past experience gleaned from combined cycle
and conventional fossil fuel fired power plant industry experience. Much of this industry
experience information has been widely communicated in public forums and literature. Even so,
it is extremely useful to include an industry expert or two in these reviews.
2-15
The EPRI HRSG Tube Failure Manual2 and the EPRI report on Delivering High Reliability Heat
3
Recovery Steam Generators provide numerous examples of cycle chemistry and thermalmechanical influenced HRSG pressure part failures and the underlying factors that influence
these failures. These references should be thoroughly reviewed to identify potential operational,
maintenance or design features that may be relevant to the unit/pressure part/feature being
assessed.
It has also been found useful with regard to thermal-mechanical influenced damage to review the
loading modes that have been associated with failures. Some of the key loading modes that have
led to pressure part failures have been summarized in the Evaluation and Control of Creep-,
Corrosion- and Thermal Fatigue of HRSG Pressure Parts5 report. These should be reviewed for
each section/pressure part/feature of the HRSG to identify where damage may occur and what
diagnostic/troubleshooting instrumentation is needed to quantify the severity of the loading of
concern.
Appendix B provides an example of the process used to identify potential issues. During this
evaluation every section of the HRSG from the first gas touched tube bundles (e.g., the final
reheater) to the last gas touched tube bundles (e.g., the preheater) should reviewed and assessed.
For each section of the HRSG the following questions should be addressed:
What thermal-mechanical load influenced pressure part failures could occur in this section of
the HRSG or have occurred in units with similar operating, maintenance, or design
attributes?
2.4 Step 3: Specify the Type and Locations for the Diagnostic
Instrumentation
Working with the plant staff, specify the location and type of instrumentation that will need to be
monitored for the cycle chemistry and that will need to be installed for the thermal transient
diagnostic/troubleshooting/improvement tests. In the cycle chemistry area this will also include
grab sampling for iron in the feedwater and evaporator circuits. The specific procedures and
controls to be used prior to and during the operational transients that will be evaluated will also
be defined and communicated.
For example, it may be recommended that some preliminary tests, evaluations and improvement
of the full load chemistry be performed and implemented prior to performing transient thermal
and cycle chemistry tests. These might involve testing oxidation-reduction potential (ORP), feed
and drum water iron level (with and without the feedwater reducing agent) then adjusting
feedwater ammonia level and the drum water solid alkali additives to optimal levels (Figure 2-5).
2-16
Hydrazine
16
Dissolved Oxygen
ppb
14
Iron Level
12
10
8
6
4
2
7/1/2003
6/30/2003
6/29/2003
6/28/2003
6/27/2003
6/26/2003
6/25/2003
6/24/2003
6/23/2003
6/22/2003
6/21/2003
6/20/2003
6/19/2003
6/18/2003
6/17/2003
6/16/2003
6/15/2003
6/14/2003
6/13/2003
6/12/2003
6/11/2003
6/10/2003
Figure 2-5
Example of a preliminary 21 day in-situ test to confirm that reducing the injection of
hydrazine does reduce the total level of iron in the feedwater. Subsequently on this unit,
the reducing agent was eliminated.
Most of the combined cycle units will have an adequate array of core cycle chemistry monitoring
instrumentation. A listing of cycle chemistry monitoring parameters and monitoring points is
provided in Table 2-2. The core parameters are considered the minimum level of surveillance
that is needed for all HRSG units. In general, use of on-line analyzers for continuous analysis of
chemistry is preferred. However, some provision is made for use of shared instrumentation
(dissolved oxygen) and laboratory analysis of grab samples (silica and phosphate). The
monitoring approaches suggested recognize limitations on manpower at many HRSG plants and
the fact that some analyzers require significant maintenance attention to perform reliably.
The listing of Suggested Additional Monitoring or Diagnostic Parameters indicated in
Table 2-2 represents those chemistry surveillance measures most likely to be included in
customized chemistry programs for specific plants and units. It is anticipated that this existing
instrumentation will need to be supplemented by some grab sampling (particularly of iron).
2-17
Specific Conductivity
Continuous by On-Line Analyzer
pH
Continuous On-Line Analyzer
Dissolved Oxygen
Continuous by On-Line Analyzer
(May Be Shared)
Sodium
Continuous by On-Line Analyzer
Phosphate
Grab Sample Analysis Each Shift
(Or Continuous by On-Line Analyzer)
Silica
Grab Sample Analysis Each Shift
(Or Continuous by On-Line Analyzer)
Treated Makeup
Still other chemistry parameters that may be monitored under special circumstances include the
following:
2-18
Copper in Feedwaterto evaluate feedwater treatment in HRSG units with copper alloys
(HRSG/combined cycles usually have copper-free feedwater systems, but may have copper
alloys in the condenser.).
Sulfate and Chloride in Treated Makeup, Condensate, Condensate Polisher Effluent and
Steamto evaluate cycle contamination and transport involving these species.
Total Organic Carbon (TOC) in Feedwater, Boilerwater and Steamto assess the effect of
organic based proprietary treatments and makeup contamination on cycle chemistry.
Analyzers suitable for low level analysis of anions and organics are not expected to be included
in an HRSG plant laboratory. Such testing would need to be contracted to an outside laboratory
with an ion chromatograph (for anions) and a TOC analyzer (for organics).
Water chemistry commissioning should be a part of the total commissioning effort during which
a new unit or a retrofitted unit is transferred from the supplier to the operator. The main
objectives of the commissioning are:
To determine the chemical transport characteristics of the cycle and final selection of water
treatment, water and steam chemistry limits.
This is the primary focus of the monitoring campaigns to be performed within this project to
select the optimum evaporator water and feedwater treatments. There have been too many units
where commissioning has not been performed at all or has been performed insufficiently,
resulting in major equipment damage within weeks or months of the initial operation. Typical
problems that can be avoided by proper commissioning include:
Destruction of the magnetite on HRSG boiler tube surfaces and flow-accelerated corrosion
(FAC).
Severe hideout of water treatment chemicals, such as sodium phosphate, resulting in deposits
and corrosion.
Dryout or onset of departure from nucleate boiling in evaporator tubing which may lead to
overheating or underdeposit corrosion such as caustic gouging, hydrogen damage or acid
phosphate corrosion.
High carryover leading to superheater, reheater, and turbine deposits and superheater and
reheater overheating failures.
Dirt, debris or corrosion products left in the boiler or elsewhere in the system resulting in
buildup of deposits or foreign object damage.
The water chemistry-related systems and functions that should be tested during commissioning
include:
2-19
Feedwater corrosion product generation and transport (determination of the points where the
corrosion occurs).
Evaporator carryover.
Pretreatment system.
The importance of comprehensive monitoring/commissioning for all types of HRSGs units and
treatments cannot be overemphasized.
Most combined cycle units will also have an adequate array of core thermal hydraulic monitoring
instrumentation (Table 2-3). It is very likely that additional diagnostic/ troubleshooting
thermocouples will need to be installed. The locations recommended for attachment of
thermocouples to tubes and headers will be based on experience obtained from previous projects
performed on HRSGs with somewhat similar design features in conjunction with the following
general guidelines applicable to horizontal gas path (HGP) HRSGs.
2-20
Monitoring Points
Fluid pressure
Fluid temperatures
Fluid levels
Valve positions
2-21
Monitoring Points
HPSHs and RHs of all designs of HRSG are vulnerable to damaging tube-to-tube temperature
differences caused by undrained condensate blown forward when significant steam flow is
initiated during each CT/HRSG startup due to one or more of the following design deficiencies:
No means provided to drain condensate from all blind ends of headers, pipes and manifolds.
Drain connections on headers, pipes and manifolds are too small to quickly remove all
condensate during starts from low pressure in HPSH or RH.
Drains from different sections of HPSH (or RH) are interconnected with drains from other
sections of HPSH (or RH) that normally operate at different pressures, (instead of each
section that operates at a different pressure being individually piped all the way to the
manifold on the blowdown vessel).
Condensate pools along the bottom of long headers, interconnecting pipes and manifolds
because they were installed with inadequate fall in the direction of normal steam flow in cold
and/or hot operating conditions to ensure all condensate does drain to drain connections.
Inadequate height difference between bottom drain points on HRSG and drain manifold on
the blowdown vessel to accommodate condensate collection pots, positive fall in drain pipes
all the way to the tank, sufficient static head on RH drain lines to provide adequate drain flow
rate from RH when at or close to atmospheric pressure.
Drain flow rates from HPSH drains are not automatically regulated as a function of HP
pressure to prevent excessive HPSH drains flow from overpressurizing the blowdown vessel.
HPSH and RH drains taken to the same blowdown vessel and causing reverse flow of a
mixture of steam and slugs of water from blowdown vessel into RH when simultaneously
draining HPSH and RH.
2-22
Condensation occurs in HPSH tubes whenever the gas temperature at inlet to the HPSH tubes is
below the saturation temperature in the HPSH tubes. This is likely to occur during deceleration
of the CT after firing ceases at every shutdown and in substantial quantities during every prestart
purge before CT firing commences. The second common source of significant quantities of
condensate in HPSH sections is in-leakage of feedwater at interstage desuperheaters due to
leakage past the spraywater control valve when notionally closed if the block valve is open and
the feedpump running, and even past the block valve when notionally closed due to erosion at
the valve seat. When HP superheater pressure is low the high pressure drop across the spraywater
valves when the boiler feedpump is running will pass significant quantities of feedwater through
small leakage paths.
Condensation in RH tubes is most prevalent when cooling during offload periods and during
prestart purges of a cold or cool HRSG with the HP drum at or close to atmospheric pressure.
However, experience from testing several HRSGs installed with TCs on HPSH and RH tubes is
that RH tubes are particularly susceptible to tube-to-tube temperature differences caused by
blowing forward of undrained condensate, not just during cold and cool startups, but also during
hot and warm startups. Furthermore, RH tubes usually experience much larger, very damaging
tube-to-tube temperature differences than HPSH tubes because steam flow and forward pressure
drop cannot be established in the RH until a later stage in the startup than in the HPSH by when
the gas temperature and that of the uncooled tubes is higher. One common sources of undrained
condensate in RHs during startups is in-leakage of attemperator feedwater past passing valves
when the boiler feed pump is running. Another source of potentially substantial quantities of
undrained condensate in the lower manifold, interconnecting pipes and headers of RHs is reverse
flow through the RH drain pipes of substantial quantities of saturated steam, in some cases of
subcooled water, from the common blowdown vessel used for HPSH and RH drains, which
becomes pressurized to above the RH pressure when simultaneously attempting, as necessary, to
drain the HPSH and RH sections prior to establishing forward steam flow through the HPSH and
then the RH. A further source of damage in reheaters is condensate migration forward from cold
reheat pipes when steam flow from the HP steam turbine is established. Substantial condensate
forms during warming from long, large cold reheat pipes between the steam turbine and the
HRSG, and from leakage past eroded seat of the HP bypass attemperator spraywater block
valves, which deficient cold reheat pipe drainage arrangements often cannot quickly remove. An
example of the results from an instrumented RH is shown in Figure 2-6.
2-23
Figure 2-6
Example arrangement of a set of thirteen diagnostic/ troubleshooting thermocouples that
identified and quantified the magnitude of cold startup related row-to-row and element-toelement tube temperature differences in an HRSG reheater bundle. Prior to introducing
steam flow (at approximately 38 minutes after combustion turbine startup) the leading row
tubes (Row A) were approximately 55oC (100oF) hotter than the trailing, Row B tubes. After
introducing steam flow, two of the leading row tubes near the right hand side of the bundle
were rapidly quenched to near the estimated saturation temperature. This forward flow of
saturated liquid (most likely undrained condensate) resulted in a tube to tube temperature
difference near 140oC (250oF). In more recent tests on another design of HRSG tube-to-tube
temperature differences in excess of 167oC (300oF) were recorded.
Significant tube-to-tube temperature differences have been measured in both HPSH and RH
steam heating sections downstream of the desuperheaters during loading ramps at startups and
during deloading ramps at normal shutdowns. The propensity for overspraying is greatest on
HRSGs supplied with exhaust gas from the GE 7/9 FA combustion turbine because of its very
high exhaust gas temperature at relatively low CT generator outputs when steam flow rates are
low. When the HP pressure is simultaneously being raised, which further reduces the HP steam
flow through HPSH and RH, then both HPSH and RH can overspray down to or below
saturation temperature, which results in significant differences across the duct in steam
temperature at tube inlet and outlet of the downstream tube row(s).
Condensate or wet steam cannot be detected in HPSH or RH tubes unless temporary
thermocouples are spot welded to a representative proportion of tubes as illustrated in Figure 2-6.
It is recommended that, where physically accessible, a thermocouple is attached to the top and
2-24
another to the bottom of tubes on the bare section of tubes between the finned tube section and
the header attachment weld behind the gas baffles using the following tube selection criteria:
TCs should be installed on tubes identified by previous testing experience on other HRSGs
with similar tube/header/desuperheater arrangements more susceptible to steam
condition/tube temperature anomalies.
The final steam heating sections of HPSH and RH are particularly susceptible to large tubeto-tube temperature differences and utilize the largest portion of the TCs in the HPSH and
RH sections.
Judicious selection of a few tubes most susceptible to condensate chilling in all earlier
heating sections of HPSH and RH to identify all potential sources of undrained condensate.
Where HPSH and/or RH heating sections downstream of desuperheaters have more than one
parallel-pass rows of tubes, it is important to install TCs on adjacent tubes of all rows
because condensate/wet steam sometimes preferentially flows in tubes of one row.
Tubes closer to the inlet branches on the inlet header of the final heating section of HPSH
and RH are particularly susceptible to chilling by condensate or saturated steam.
Tubes close to the blind end of headers are susceptible to condensate chills by undrained
condensate trapped at the end of the header where there is no local drain connection.
Where the arrangement of inlet and outlet steam pipes results in the tubes across the duct
having different pressure drops, tubes with lower and higher pressure drops need to have
TCs.
Tubes supplied by an inlet pipe downstream of the desuperheater that is closest to the
desuperheater are more susceptible to chills by incompletely flashed desuperheater
spraywater.
Tubes supplied by an inlet pipe downstream of the desuperheater that is furthest from the
desuperheater are more susceptible to chills from excessive quantities of spraywater from
desuperheaters, and also from quenches by undrained condensate.
TCs should be fitted to the top and bottom of a front row and rear row tube and also to the
downcomer of each of the HP, IP and LP evaporator to determine the maximum tube-to-tube and
tube to downcomer temperatures to be accommodated by appropriate flexibility. These
thermocouples will also evaluate the severity of subcooling that occurs in each evaporator during
extended warm shutdowns.
All types of economizer/preheater design have the potential to develop significant thermal
stresses due to tube-to-tube temperature differences. However locations of potential high
thermal stresses associated with tube-to-tube temperature differences is strongly influenced by
the type of economizer design employed. Furthermore, the susceptibility of the particular type of
economizer to significant thermal stresses is also influenced by the extent to which its propensity
to high thermal stresses has been mitigated in the installed detailed design.
2-25
Figure 2-7
Example of the location of twenty eight diagnostic/ troubleshooting thermocouples
installed in a vertical tube high pressure economizer tube bundle.
Thermocouples A1, 3, 7, 13, 17, 21 and 23 were installed above the gas seal on the vertical
upflow tubes just beneath the outlet header. Thermocouples B2, 4, 6, 12, 18, 22 and 24
were installed above the gas seal and below (downstream of) the return bend closest to
the outlet. Thermocouples C1, 3, 7, 13, 17, 21 and 23 were located above the gas seal and
below (downstream of) the return bend closest to the inlet. Thermocouples D2, 4, 8, 12, 18,
22 and 24 were located on the vertical downflow tubes just beneath the inlet header and
above the gas seal.
2-26
Figure 2-8
Seven high pressure economizer tube Row A (just beneath the outlet header, see Figure
2-7) thermocouples measurements during a cold start. At this location the measurements
suggest that the HP economizer approach temperature is at least 10oF (6oC) and the tube to
tube temperature differences are less than 25oF (14oC). No steaming or severe tube to tube
temperature differences would be indicated from these thermocouples.
Figure 2-9
Seven high pressure economizer tube Row B (just after the final upper return bend, see
Figure 2-7) thermocouples measurements during a cold start. At this location the
measurements indicate that the water in four of the seven tubes is more than 25oF (14oC)
above the estimated saturation temperature (i.e., air-locking or steaming is occurring in
the tubes near the edges of the bundle). This resulted in a tube to tube temperature
difference near 80oF (44oC).
2-27
Figure 2-10
Seven high pressure economizer tube Row C (just after the first upper return bend, see
Figure 2-7) thermocouples measurements during a cold start. At this location the
measurements indicate that the water in one of the seven tubes is more than 10oF (6oC)
above the estimated saturation temperature (i.e., air-locking or steaming is occurring in at
C23). Since the water in the other tubes is more than 100oF (55oC) below the saturation
temperature this results in a tube to tube temperature difference that is greater than 100oF
(55oC).
2-28
Figure 2-11
Seven high pressure economizer tube Row D (in the vertical downflow tube just beneath
the inlet header, see Figure 2-7) thermocouples measurements during a cold start. At this
location the measurements indicate that the water in the three cooler tubes, which are
probably representative of the majority of tubes in the row, remains close to the HP
economizer feedwater inlet temperature, whereas the fluid in the other tubes with TCs (that
are close to the blind ends of the inlet header and further from the inlet pipes on the
header) operate up to 67oC (120oF) hotter than the coldest tubes due to either flow
stagnation or reverse, recirculating flow upwards in the tubes with the lowest pressure
drop between the upper inlet and lower return header. Lower flow and high temperatures
in the tubes furthest from the inlet pipes were caused by higher hydraulic resistance and
buoyancy forces in the water in these tubes. Gas laning and elevated heat absorption in
the tube circuits near the sides of the bundle may have been partially responsible for the
increased buoyancy forces, reduced flow and elevated water temperature observed.
Appendix B provides additional examples of thermocouple placements for the specific tube
bundle of a horizontal gas path HRSG that has operational and design features that have been
extensively monitored in units of similar design. Drawing from the experience and knowledge
gleaned from the more extensive evaluations of the similar units it was possible to select a
minimum number of locations for diagnostic/troubleshooting thermocouples. For units without
this prior experience more extensive thermocoupling would be needed to ensure that all the
significant and damaging thermal-mechanical loads are identified.
thermocouple type used for measuring tube metal/ fluid temperatures are capacitance discharge
welded directly to the outside surface of unfinned sections of tubing near the headers. These are
attached with the two thermocouple junctions approximately 0.06 in (1.5 mm) apart. This
provides a junction that responds rapidly to fluid temperature changes. The thermocouple
junctions are covered with insulation to ensure that the tube metal/ fluid temperature is being
measured rather than some average tube/gas temperature as would result with uninsulated, pad
type thermocouples.
Special care is required when attaching thermocouples to Grade 91 components. This material is
susceptible to severe hardening during welding and is more sensitive to weld imperfection than
lower alloy materials. A high degree of care should be made to ensure that the surfaces for the
thermocouple junctions are clean, dry and adequately preheated. It is recommended that weld
qualification testing is performed to demonstrate that the capacitance discharge welding process
and procedure produces adequately fused, crack free welds.
2-30
2-31
Figure 2-12
Time line plot of the bulk temperatures measured up and downstream of a single parallel
pass, two row, vertical tube, finishing (high temperature) reheater during a warm start
made with a low hot reheat steam temperature setpoint4. Two significant temperature
drops were observed. The first occurred soon after steam flow was established through
the reheater bundles and was attributed to forward flow of undrained condensate. The
second event was more severe and was caused by overspraying of the interstage
attemperator too close to saturation temperature. Operating practices that contributed to
the overspraying were substantial lowering of the RH steam outlet temperature setpoint
and excessively aggressive ramping of the CT load and exhaust gas temperature to the
maximum gas temperature. Simultaneous raising of HP pressure exacerbated the severity
of the event. (Source: Reference 4)
2-32
Figure 2-13
Spatial temperature plot of 74 reheater tube thermocouples. This time slice was associated
with the attemperator overspray event shown in Figure 2-12. Some tubes were more than
83oC (150oF) hotter than the adjacent tubes. The tubes near the inlet nozzle centered above
tube element #9 were severely cooled in both tube rows. Near the other inlet nozzles the
dogleg tube row (Row #2) was being cooled well below the straight, leading row of tubing.
(Source: Reference 4)
It has generally been found that optimizing the operational procedures to minimize the problems
should be done before more expensive design alterations are considered. After corrective actions
are made additional tests should be performed to determine the benefit of operational changes. In
addition the role of maintenance activities should not be overlooked. Two maintenance issues
that should be given attention with regard to prevention of undesirable thermal events are the
inspection and refurbishment of drain lines, and maintenance of attemperators and their thermal
shields and block valves.
2-34
3
REFERENCES
1. a) Interim Cycle Chemistry Guidelines for Combined Cycle Heat Recovery Steam
Generators (HRSGs). EPRI, Palo Alto, CA., TR-110051, Nov 1998
b) The first revision of this guideline will be published at the end of 2005 as: EPRI, Palo
Alto, CA, 1010438
2. Heat Recovery Steam Generator Tube Failure Manual, EPRI, Palo Alto, CA, TR-1004503,
Nov 2002
3. Delivering High Reliability Heat Recovery Steam Generators EPRI, Palo Alto, CA: TR1004240, Mar 2003
4.
5.
Evaluation and Control of Creep-, Corrosion- and Thermal Fatigue of HRSG Pressure Parts,
EPRI, Palo Alto, CA, Mar 2005, 1008090
6.
R.B. Dooley, and R. Tilley, Tube Failures in Conventional Boilers and Combined Cycle/
HRSGs, International Conference on BTF and HTF and Inspections, San Diego, CA, Nov
2004. Published in PowerPlant Chemistry, 2004, 4(12)
7.
3-1
A
BACKGROUND INFORMATION REVIEW
Prior to performing detailed assessments of a given unit it is useful to thoroughly review existing
background information. Some key information that should be included in the review includes
the following:
A general description of the combined cycle plant (combustion turbine, HRSG and steam
turbine make and model).
A description of the HRSG influencing thermal systems (e.g., combustion turbine exhaust
gas temperature and flow characteristics, duct/damper/stack system, tube bundle/ header/
drum/piping/ vent/drain/ layouts, attemperator, valve, pump and instrumentation locations).
Steam conditions required for steam turbine startup from different initial condition including
maximum steam to metal mismatches and recommended steam temperature ramp rates, hold
points and durations.
Sectional arrangement drawings of HRSG pressure parts and interconnecting pipes, vents,
drains, including vertical cross section through gas duct between inlet duct and stack, vertical
front view drawings of each heat transfer panel, and plan views at different elevations.
Piping & instrumentation diagrams for HRSG steam and water circuits, cold and hot reheat
steam pipes to steam turbine, high pressure and hot reheat steam bypass/dump systems, high
pressure superheater and reheater drains, etc.
Heat balance diagrams for each fuel, at baseload and part loads for range of ambient
conditions
Sectional arrangement sideviews, plan and front views of the HRSG, showing external
interconnecting pipes, principal valves, attemperators, pipe drain points, superheater and
reheater drain points and pipes and valves to blowdown vessel, etc.
History of any HRSG failures and the corresponding failure analysis and/or root cause
reports
The general layout and description of the cycle chemistry features of the unit: e.g., makeup/
return condensate characteristics, fluid circuitry, locations of existing instrumentation, typical
operating values of the continuously monitored chemical parameters around the cycle,
locations of chemical feeds, description of feedwater and evaporator water chemical
additives; with all information displayed on a cycle chemistry diagram. Any ancillary
information about the cycle chemistry will also be needed. In this category the levels of iron
at various points (feedwater, evaporator drums) is key to the initial assessment.
A selected history of cycle chemistry records (on-line and grab sample reports), ish needed to
confirm deficiencies or other significant findings of the cycle chemistry diagram compilation.
This should include: (i) printouts of most recent half dozen grab sample results (if
measurements were made on site and by on off site laboratory then evaluate both) and (ii)
printouts of the on-line measured cycle chemistry for the same time periods as the grab
samples plus a printout for selected full load operating conditions including the most recent
full load operating period.
The combustion turbine exhaust gas characteristics during startups and shutdowns and over
the full range of operation
Currently used operating practices, limits and controls for startup and shutdown of the lead
and lag units
Side and front views of each section of the HRSG showing the tube to header configurations,
number of tube bundles, materials lists, thickness, diameter, baffle plates, vents, drains,
headers, supports and clearances
Any design or other calculations that address the cyclic life of any HRSG pressure part
Detailed arrangement drawings of the drain systems all the way to the blowdown
DCS historian electronic records plotted versus time (using 5 second time intervals) of key
parameters such as those in Table A-1 for wide range of operating transients (see Section
2.2.3).
For most parameters the plots should be based on the measured median value of the
parameter for 5 second time intervals. For attributes such as combustion and steam turbine
output (MW) or fuel consumed the cumulative values should be used.
A-2
When creating plots of ramp rates the following relationship has been found to produce
meaningful estimation of the ramp rates that have a sufficient duration to produce damaging
temperature gradients through the thickness of the pressure parts being assessed.
dT/dt = (Ti Ti-10)/10 minutes
(A-1)
Where:
dT/dt = Rate of change of temperature (oF/min or oC/min)
Ti = measured temperature at the current time
Ti-10 = measured temperature 10 minutes earlier
Table A-1
DCS Attribute Grouping Useful for Identifying and Characterizing Thermal-mechanical Cycles
Location
Overall unit
characteristics
Combustion
turbine
Overall unit
characteristics
Key HRSG
Attributes
Overall unit
characteristics
Steam turbine
HP superheater
Comments
These plots can be used to
identify the beginning of
shutdowns, the prestart purge,
the end of startups and a
multitude of key characteristics of
the stop/start cycles
A-3
Reheaters
Reheater ramp
rates
HP evaporator
HP evaporator
ramp rates
LP/IP/HP
Economizer/
Preheater
Comments
Identify temperature hold periods
by viewing the ramp rate plot in
conjunction with the timeline plot
of the same attributes.
May be useful to add a curve for
the estimated saturation
temperature based on measured
pressure
Use separate plots for
temperatures, pressures, flows,
and valve positions
Plots of DCS parameters should be assessed to determine if optimal shutdown and startup
procedures are being used. Discussions with the plant operators and input from individuals well
A-4
versed in design of HRSG operational procedures should be included in this review. A few of the
key questions which should be addressed include:
During shutdowns are the combustion turbine exhaust temperatures being controlled to
values near the estimated high pressure superheater steam saturation temperature so that
severe tube to header and condensate quenching of the lower headers are avoided?
During startups are the HRSGs being provided with an initial heat soak with the combustion
turbine exhaust temperature being held at a minimum achievable value (~ 315oC (600oF) to
360oC (700oF)) to minimize the peak tube to header temperature differences?
During startups are the hold durations and ramp rates from the initial saturation temperature
to full load conditions within acceptable ranges for the HP drum and HP superheater
headers? Has the acceptable ramp rate limits been determined for the HPSH?
During startups or shutdowns are the high pressure superheater, and hot reheat steam outlet
setpoints being manually reduced to temperature values well below the design setpoint (avoid
over temperature trips) thus increasing the potential for attemperator overspraying and severe
tube to tube temperature differences.
Are the HP superheater and reheat bypass steam flows during hot and warm starts being
established at the same time as the combustion turbine startup to provide beneficial cooling
steam to the superheater and reheater tubing?
Detailed evaluation of the timeline plots may identify gross operational or design deficiencies or
opportunities for improvement. In a small number of cases they will provide sufficient
information to identify and correct issues that are damaging to HRSG pressure parts such as
significant attemperator overspraying events. On the other hand, these bulk measurements
cannot be used as confirmation that all is well and that no localized and damaging thermalmechanical issues are active. The underlying conditions that are creating the damaging loads for
the majority of thermal-mechanically influenced HRSG pressure part failures cannot be
identified with the conventional DCS parameters. In most cases tube, pipe, and header metal
temperature measurements are required to identify the damaging events and root causes and to
provide verification of the success of corrective actions.
A-5
B
IDENTIFYING POTENTIAL DAMAGE MECHANISMS
AND DIAGNOSTIC MONITORING NEEDS
After completing the background review it is necessary to identify potential problems and
damage mechanisms. Once the high priority potential issues and damage mechanisms are
identified then the diagnostic monitoring instrumentation and attachment locations can be
prescribed. This appendix provides an example of this phase on a triple-pressure horizontal gas
path HRSG.
Some of the guiding principles that are followed with regard to this monitoring are:
Bulk fluid temperatures will, in general, not be adequate to identify and quantify the severity
of the thermal transients that have been responsible for failures.
Severe thermal transients resulting from quenching of a few tubes within a superheater or
reheater tube bundle with attemperator spraywater or undrained condensate, etc., or chilling
of a few tubes in the feedwater inlet row of LP economizes/preheaters, which has been
responsible for numerous tube to header or drain to header fatigue failures, cannot be
detected or quantified unless thermocouples are bonded to many of the tubes to determine the
tube-to-tube and tube-to-header temperature differences.
Transient temperature differences between tube rows and downcomers of evaporators that
occur when establishing circulation cannot be detected or quantified unless thermocouples
are bonded to several tubes and pipes of the evaporators. These have been responsible for
failures in evaporator pressure parts.
Fast response thermocouples, with their junction attached directly to the tube (not the welded
sheath type connection) have been successful in measuring the damaging transients on
several designs of HRSG.
Damaging thermal transients in tube bundles are cause by a combination of the occurrence of
significant transient tube-to-tube temperature anomalies in conjunction with pressure part
design features that locally intensify the resulting thermal forces and stresses. Thus the
selection of thermocouple locations requires:
A thorough review of the design, arrangement and support of tubes and headers, of
interconnecting pipes and locations of header nozzles in each section of the HRSG; and
additionally of the location of drains on the headers, pipes and manifolds, and of
attemperators in superheater and reheater sections, of tube bundles and interconnecting
pipe flexibility, and of venting in economizers and preheaters, recirculation arrangements
for preheaters, etc.
B-1
A review of DCS time line plots to identify potentially damaging conditions during
startups from different initial conditions, during stable on-load operation and during
shutdowns.
Knowledge of the types of thermal-mechanical loads that may lead to fatigue damage in
specific tube bundles. Some guidance is provided in Chapters 4 and 7 of Reference 3 and
in Reference 5. Other types of thermal-mechanical loading mechanisms have been
identified in more recent analysis of results from diagnostic monitoring.
Personnel Involved
A cursory review of plant information should be performed prior to an on-site working meeting.
Once this is completed then a one day on-site working meeting should be sufficient to complete
the Phase II activities. To be effective, the following individuals, as a minimum, should be
involved with the unit reviews and decisions regarding the extent and specific installation
locations of diagnostic instrumentation to be added to the unit:
Plant Manager
Plant Operator
Plant Engineer
Maintenance Superintendent
Corporate Chemist
A consultant with extensive experience in HRSG cycle chemistry issues and solutions
Objectives
The following are the objectives of these reviews:
Thermal-mechanical
B-2
Approximately 5 hours of review are required with the consultants, the plant engineer and the
corporate chemist performing walkdowns of the unit, reviewing specific cycle chemistry, plant
historian data, and tube bundle drawings and discussing potential issues of concern. The results
of this effort are summarized as follows:
Cycle Chemistry Issues of Concern
Recommended actions:
Phosphate hideout in HP evaporator
Ongoing phosphate/pH/conductivity monitoring of the HP drum water
Videoprobe examination of leading row HP evaporator tubes
Review of gas temperature profile, circulation ratio at various fired and unfired
operating conditions
High (~10 ppb) iron levels in IP systems (If a feedwater reducing agent was not used, then the
concern here would be for two-phase flow accelerated corrosion)
Recommended actions:
Ongoing iron monitoring including some detailed monitoring performed during thermal
transients and following IP drum blowdown
Thermal/creep fatigue at tube to header connections and boreholes due to forward flow of
condensate/leaking or excessive attemperator spraywater into row 1 or 2 (the
attemperator was located between RH1 and RH2 near the top of the unit)
B-3
Final (high temperature) high pressure superheater bundle (HPSH2) (two sequential pass
tubes with 2.5-inch (6.35 cm) thick outlet header constructed in P91)
High tube to header temperature gradient (potential for cracking in boreholes and tube to
header welds) due to excessive steam pressure/temperature ramp rates (may need to severely
restrict ramping to ameliorate damage rate)
5 to 10 year issue
Actions:
Need to determine what ramp rate and temperature gradients are acceptable
Tube to header connection thermal or creep fatigue due to forward flow of undrained
condensate during startup
5 to 10 year issue
Actions:
Review drain operating logic for various transients
Install thermocouples on selected tubes to verify complete draining of condensate; if not
modify design and/or operation to eliminate forward condensate migration
Primary (low temperature) reheater (RH1:Two parallel passes of 2 sequential row of tubes, 4
tube rows just downstream of duct burners, 377oC (712oF) inlet steam/ 555oC (1038oF) outlet
steam with duct burner)
Accelerated creep due to duct burner heat maldistribution, heat transfer above design
Creep/ fatigue at tube to outlet header connections due to high temperature rise through RH1
tubes at steady state/ duct firing
Tube to outlet header or tube to tube temperature differences caused by condensate migration
from cold reheat pipes or leaking HP turbine bypass attemperator water
B-4
Thermal fatigue at the tube to inlet header connections due to first admission of HP bypass
exhaust steam into the hot reheater tubes and cold headers and/or condensate or leaking HP
turbine bypass attemperator water
Backflow of leaking attemperator water at low steam flow conditions during shutdowns or
starts
1 to 5 year issue
Actions:
Maintain leak tight attemperator block valves
Determine and control the gas temperature/fluid temperature/fluid flow v. attemperator
block valve control (highest risk during shutdown)
HP Evaporator
Actions:
Perform analysis to determine safe limits/ cyclic life
Install thermocouples on top & bottom of each downcomer and 1st and last row riser
tubes
Prepare and use ramp rate monitoring system
High deposition and underdeposit corrosion due to local steam films in leading row during
duct firing
Thermal/corrosion fatigue at upper return bends and tube to header welds due to water
leaking from inlet leg drains and back into hot legs of economizer
Air- and/or vapor-locks at some upper bends causing stagnant flow in some tubes (especially
in the final high pressure economizer)
Chilling of inlet tubes rows of preheater by introduction of cold feedwater into hot tubes
/headers during startup
The thermal mechanical issues that were selected for further diagnostic instrumentation study
with were:
Gas/ tube temperature maldistributions during low load and duct firing
Temperature ramp rate issues in the high pressure superheater and high pressure evaporator
Forward flow of condensate (either formed during pipe warming or from leaking HP bypass
attemperator spraywater) from cold reheat pipes into the downstream reheater tubes
Forward flow of undrained condensate or attemperator spray water into selective high
pressure superheater tubes
B-6
Forward flow of undrained condensate or attemperator spray water into selective reheater
tubes
Table B-1 and Figures B-1 through B-5 document the locations where diagnostic thermocouples
were specified.
Table B-1
Location and Number of Diagnostic Thermocouples
Location
Number of
thermocouples
32
Comments
Tube bundle A: 5 element x 2 rows x top & bottom of
each row
Tube bundle B: 3 element x 2 rows x top & bottom of
each row
HPSH2 tubes
14
18
HP evaporator
Preheater
15
B-7
Reheater #2:
RH2_T3
RH2_T4
RH2_T1
Thermocouples placed
between the header and
finned section of tubing on
the top and bottom of both
tube rows
RH2_T2
55
46 45
33 32
13
East
side
1
Figure B-1
Location of thirty two thermcouples to be installed in direct contact with the tube OD
surface between the finned tubing and the headers (Tube bundle A: 5 elements x 2 rows x
top & bottom = 20 thermocouples, Tube bundle B: 3 elements x 2 rows x top & bottom = 12
thermocouples).
Due to the stiff, parallel flow reheater bundle design, (with two rows of tubes connected to
a single inlet (bottom) and a single outlet header and dogleg bends) it was decided that the
top and bottom of each row of tubing should be instrumented. This instrumentation
configuration provides an optimal setup to identify severe events involving either forward
flow of undrained condensate or excessive attemperator flow into either of the two parallel
tube rows. The tube elements selected were based on identifying those elements with the
greatest potential to become selectively quenched by undrained condensate or excessive,
poorly distributed attemperator water, plus at least one tube element which is likely to be
representative of the temperature of most of the tubes. Each lower header has two 2-inch
(5 cm) NPS drains connected together into a 2-inch (5 cm) NPS line with the drains from
the second tube bundle. With the unit off-line the drain line gently sloped downward to an
atmospheric blowdown reservoir.
B-8
HP superheater #2:
Thermocouples placed
between the header and
finned section of tubing on
the top and bottom of the
gas inlet tube row
HPSH2_T2
HPSH2_T1
West
side
East
side
Top, Inlet
Bottom, Outlet
35
27 22 21 16
Bottom, Inlet
Figure B-2
Location of fourteen thermocouples to be installed in direct contact with the tube OD
surface between the finned tubing and the headers (Tube bundle A: 7 elements x leading
row x top & bottom = 14 thermocouples, Tube bundle B: none).
Due to the single tube circuit design, it was decided that the top and bottom of the leading
tube row should be instrumented. These pairs of thermocouples will identify and quantify
the severity of significant forward flow of undrained condensate and/or excessive
interstage attemperator flow being introduced into the inlet row tubes. The tube elements
selected were based on identifying those elements with the greatest potential to become
selectively quenched by undrained condensate or excessive, poorly distributed
attemperator water, plus at least one tube element which is likely to be representative of
the temperature of most of the tubes. Each lower header has a single 2-inch (5 cm) drain
connected together into a 2-inch (5 cm) line with the drains from the second tube bundle.
With the unit off-line the drain line gently sloped downward to an atmospheric blowdown
reservoir.
B-9
RH1_T2
RH1_T1
East
side
54
48
31
24
17 16
Figure B-3
Location of eighteen thermocouples to be installed in direct contact with the tube OD
surface between the finned tubing and the headers (Tube bundle A (duct burner fuel inlet
supply side of unit): 6 elements x gas inlet row x top & bottom = 12 thermocouples, Tube
bundle B: 3 elements x gas inlet row x top & bottom = 6 thermocouples).
Even though this reheater has a parallel circuit configuration, due to the row to row
flexibility of this reheater bundle design, it was decided that only the top and bottom of the
leading tube row should be instrumented. Previous experience with similar designs had
found that the longer, circuit with the larger diameter lower header had the greatest
potential to experience severe thermal quench events due to either undrained condensate
or introduction of excessive attemperator spray into the cold reheat piping system. The
tube elements selected were based on identifying those elements with the greatest
potential to become selectively flooded with undrained condensate or excessive, poorly
distributed attemperator water, plus a few tube elements which are likely to be
representative of the temperature of most of the tubes.Each lower header has one 2-inch
(5 cm) drain connected together into a 2-inch (5 cm) line with the drain from the second
tube bundle. With the unit off-line the drain line gently sloped downward to an
atmospheric blowdown reservoir
B-10
HP Evaporator :
To HP Evaporator
Remote Steam Drum
IPSH (Elements 1, 3, , 35)
HPEvap_T3
HPEvap_T1
West
side
HPEvap_T4
HPEvap_T2
Thermocouples placed
between the header
and finned section of
tubing on the top and
bottom of the gas inlet
tube row and gas
outlet row and at the
top, bottom and 1/3
height position on the
east-most downcomer
pipe
8 4
East
side
Top
1/3 from
bottom
Bottom
Figure B-4
Location of three thermocouples to be installed in direct contact with the OD surface of
the downcomer on the east tube bundle (One near the top of the downcomer, one near the
bottom of the downcomer, one located 1/3 of the way up the downcomer and 6
thermcouples to be installed in direct contact with the tube OD surface between the finned
tubing and the headers (at the top and bottom of the gas inlet row on elements 4 and 8 and
at the top and bottom of the gas outlet row on element 4)).
The purposes of the HP evaporator thermocouples are to determine if subcooled water
stratifies to the lower portion of the evaporator during long weekend shutdowns, also
whether the rear row tubes transiently act as downcomers or stagnate and overheat when
recirculation is being established, resulting in unanticipated thermal transients when
natural circulation begins during the startups from different initial conditions.
B-11
LP Preheater:
LPEcon_T3
Thermocouples placed
between the header and 1st
upper return bend and
finned section of tubing on
the top and bottom of the
feedwater inlet tube rows
LPEcon_T1
LPEcon_T2
West
side
East
side
Outlet nozzle
19
Inlet nozzle
13
Figure B-5
Location of fifteen thermocouples to be installed in Bundle A in direct contact with the
tube OD surface between the finned tubing at three locations on 5 tube elements, i.e., one
close to the upper feedwater inlet header, another at the bottom of the inlet row tube near
the first lower return header and the third just below the first (in direction of feedwater
flow) upper return hairpin bend; 3 thermocouples on each of 5 elements = 15
thermocouples.
Thermocouples were located to evaluate: (i) introduction of cold feedwater into hot tubes,
(ii) steaming and/or air blockage in upper return bends, (iii) gas laning along edges of
preheater tube bundles, (iv) introduction of hot recirculation water into cool feedwater inlet
row tubes after forward flow is interrupted.
B-12
C
MONITORING GAS, FLUID, AND TUBE METAL
TEMPERATURES
The accurate determination of transient temperature distributions in tubes and headers is critical
to the accurate determination of remaining tube, pipe or header life and for root cause
investigations of pressure part failures. Methods can be either direct, primarily thermocoupling,
which provides current temperature levels, or indirect.
In some cases, existing measurements of bulk steam conditions will provide the necessary
temperature information. For example, the measured steam temperature out of the superheater
bundle just downstream of the duct burners will provide an indication of burner overfiring or
increased gas temperatures due to operating the gas turbine at part load or with the diverter
damper partially open. Also gross overspraying at attemperators is evident from the
measurement of bulk steam temperature at superheater or reheater attemperator outlets. Gross
condensate migration is sometimes, but not always, evident from bulk steam temperature
measurements.
However, to detect and quantify significant temperature differences between tubes intended by
design to always operate at closely similar temperature or to measure the potentially damaging
transient temperature gradients at tubehole and pipe penetrations of thicker headers and pipes,
additional thermocouples must be installed.
Thermocouples bonded to selected tubes are the only sure, proven means of detection of
transiently abnormal conditions, such as steaming in notionally water-wetted tubes or condensate
migration through and downshocking of superheater or reheater tubes associated with specific
operating conditions (i.e., normal load, low loads, transients, etc.). In most cases, the
thermocouples will probably need to be installed in the heat absorbing sections of the HRSG
tubing. To obtain accurate temperature measurements in these locations requires careful
thermocouple installation methods.
Various methods have been attempted for attaching thermocouples to the outer surfaces of bare
sections of tubes, with differing degrees of success. Experience with earlier attempts to measure
the bare surface temperature of tubes by clamped on thermocouples was unacceptable because
the temperatures measured by the clamped on thermocouples tended to be inconsistent
(increasingly so with time as clamps relaxed and surface oxides developed) and more susceptible
to the influence of gas temperature. Thus clamping of thermocouples to the surface of tubes is
not recommended.
Two methods that establish a positive bond between the thermocouple and tube or header surface
have been successfully used. The more durable method of these utilizes sheathed thermocouples
C-1
and bonds the thermocouple sheath to the header or tube surface with a sprayed aluminum
deposit. However this process is more costly and cannot be used on less accessible tube rows.
Also, thermocouples bonded to tubes with sprayed aluminum deposit are somewhat slower to
respond when tube temperatures are changing rapidly.
The procedure below, which spot welds thermocouple wire to the outer surface of the tube or
header, successfully overcame some difficulties with reliability and durability of welded
thermocouples. Thermocouples installed by this process have lasted for several months,
provided that the wires are routed and supported and protected carefully. They need to be
protected from weather and careless impact damage outside the HRSG.
Process Specification
Bare two ends of a type K thermocouple for a distance of about 0.5-inch (1.25 cm). Make a 90degree bend half way on each wire in the same direction. Ensure opposite ends are not
connected together (each wire isolated from the other). Do not attach thermocouples to bends, or
within 1-inch (2.5 cm) of a bend or a weld.
Sand all oxide/scale off the thermocouple attachment spot on the tube (approximate 1-inch (2.5
cm) diameter). For T91, preheat local area to 149oC (300F). For T22, preheat to 93oC (200F).
For T11 and carbon steel, preheat 93oC (200F). Using a TAU-107 Hill Technical capacitor
discharge machine, place the magnetic ground clamp within 3-inches (7.6 cm) of the
thermocouple attachment spot (pinch clamp may be used instead, - for pinch clamps, ground
may be further away on header or header attachment). When using a remote ground, over 2-feet
(60 cm) away, increase weld intensity to high (if needed). Set the TAU-107 on automatic and
medium weld intensity (manual may also be used). Grab one wire with the plier welder (or
hemostat long neck plier) and touch the tube with the wire end. The machine will "fire" in about
3 seconds on auto, (or push red button to manually fire). Using a fine piece of emery cloth or
stainless brush, remove any black firing residue from the area where the next wire will attach.
Grab the second wire; note the machine is ready to fire (green light). Pick a spot about 1/8-inch
(0.3 cm) from the first weld and no further than -inch (0.6 cm). Weld the second wire. Brush
residue with stainless wire brush.
Inspect for thermocouple leg distance less than -inch (0.6 cm). Inspect for sound welds, VT
and attempt to slightly wiggle thermocouple attachment. VT inspect for no cracks, use PT to
resolve questions (ANSI Level II or III NDT required). If any unsoundness is noted, remove
(grind) spots and shift location -inch (1.2 cm), repeat steps. Carefully grind and inspect (using
PT or MT) any weld junctions that were not successful to ensure that no cracks are left in place.
This last step is especially important for welds made to T91 tubing.
C-2
Data Recording
It is recommended that the temperature data is recorded, not on strip recorders, but electronically
on CD-ROM using portable recorders. Two recorders are probably required, one on the roof of
the HRSG for the majority of the thermocouples, the other for the thermocouples at the bottom
of the tubes. A high speed scanner can be used; a scan rate of 5 seconds is recommended with
all thermocouples recorded every 5 seconds. Data sets from each event recorded should be
assembled in spreadsheets format to facilitate plotting of selected points and time periods for
preliminary analysis and enables precise temperatures to be extracted for points of special
interest.
Some challenges and solutions associated with thermocouple installation include:
Must prepare for removal of upper baffle plates (need rigging and plan for removal, support
or lowering, and re-installation. This planning needs to be consistent with the scaffolding.
With the upper baffle plates in place it is sometimes not possible to obtain access to the
second tube row since the tube fins and baffle plate block the access. In certain cases access
to the unfinned section of the first row tubing is obstructed.
The scaffolding contractor needs to see the spacings and requirements before the outage if
possible. It is almost always possible to build workable, safe scaffolding in all spaces large
enough for a person to pass through but this may require special scaffolding sizes which
might not be available if the contractor doesnt have good knowledge of what is needed prior
to the outage. A spider climber attached through small upper access door is an alternative to
scaffolding but must be planned ahead of time to be prepared to set up the appropriate upper
support points and rigging.
C-3
Figure C-1
Removal of a window of lagging and insulation on an HP downcomer.
C-4
Figure C-2
Removal of surface oxide with gentle grinding.
C-5
Figure C-3
Preheating of cleaned surface and verification of the surface temperature with a Tempil
stick.
C-6
Figure C-4
Attachment of the work lead (attached with a magnet) and the electrode lead
(thermocouple wire held on the surface with a plier) which is electrically connected to the
capacitance discharge power supply.
C-7
Figure C-5
Completed thermocouple junction welds
C-8
Figure C-6
Supporting and guiding the thermocouple wire from the thermocouple junction to the data
acquisition system. It is important that the wire is guided in a manner that provides for
thermal expansion and protection from personnel.
C-9
Figure C-7
Insulation covering the thermocouple junctions on a HPSH tube. The insulation used was
spare manway door insulation that was held in place with two wraps of stainless steel
wire.
C-10
Figure C-8
Mock-up T91 tube that was used to qualify the thermocouple junction welding procedure.
Note the two unsuccessful welds above the completed welds. Unsuccessful weld
junctions should be removed by light grinding.
Figure C-9
Polished metallurgical cross-section of one of the mock-up thermocouple junctions.
Although this junction has some minor porosity, undercut and incomplete fusion it will
provide accurate temperature readings and will probably have adequate reliability.
C-11
Figure C-10
Cross-section through another thermocouple junction. This junction has severe porosity
and small cracks (see Figure C-11). This thermocouple junction will provide accurate
temperature readings but is not adequate if longevity and resistance to in-service cracking
are important.
Figure C-11
Close-up of the thermocouple junction shown in Figure C-10. Note the severe porosity,
and cracks that extend toward the tube surface. The tube surface beneath the weld will
have a shallow, but very hard heat affected zone. The combination of porosity,
microcracks, and the hard base metal heat affected zone could lead to cracking.
C-12
D
COST FOR A 96 THERMOCOUPLE MONITORING
SYSTEM
The following is a summary of the approximate costs to procure and install a 96 thermocouple
tube temperature monitoring system. EPRI is continually being asked for these costs, which are
needed for approval process and estimating overall costs. It must be recognized that each unit
and installation is different. So this Appendix is provided purely as an example of the features
which need to be included.
Material
Thermocouple wire.....$6,810.00
20 gage (0.0320-inch/ 0.813 mm diameter) Type K (nickel chromium, nickel aluminum)
thermocouple wire, insulated with solid ceramic fiber and Inconel overbraid for 1200oC
(2200oF) temperature rating, with special limits of error of plus or minus 0.4%) (Type
K20-2-N-350)
Conduit.....$2,000.00
PLC Network.....$33,367.00
This is a data acquisition system included for the 96 thermocouple inputs. This system
was linked with an existing PLC system used for duct burners and chillers. The data
collected by the PLC systems were fed to a server where the information was logged. The
thermocouple PLC system had the capacity to expand to 384 thermocouple inputs. The
estimated cost to add an additional 96 thermocouples is $12,000 (for the extra PLC
thermocouple input modules) plus the additional cost of the thermocouple wire ($6,810)
and extra labor ($7,500 assuming this had been performed when the scaffolding was in
place) leading to a total extra cost of approximately $26,310.
Misc - 5% of Material..............$2,108.85
Labor
Scaffolding..$20,000.00
TC Installation...$7,500.00
PLC Installation (40 mnhrs)..$3,000.00
Total Material + Labor.$74,785.85
D-1
6. EXPORT
The laws and regulations of the United States restrict the export and re-export of any portion of this package, and
you agree not to export or re-export this package or any related technical data in any form without the appropriate United States and foreign government approvals.
7. CHOICE OF LAW
This agreement will be governed by the laws of the State of California as applied to transactions taking place entirely in California between California residents.
8. INTEGRATION
You have read and understand this agreement, and acknowledge that it is the final, complete and exclusive agreement
between you and EPRI concerning its subject matter, superseding any prior related understanding or agreement. No
waiver, variation or different terms of this agreement will be enforceable against EPRI unless EPRI gives its prior written consent, signed by an officer of EPRI.
Program:
1008088
2005 Electric Power Research Institute (EPRI), Inc. All rights reserved. Electric Power Research
Institute and EPRI are registered service marks of the Electric Power Research Institute, Inc.
Electric Power Research Institute 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com