Energy Materials

Materials Science and Engineering for Energy Systems

ISSN: 1748-9237 (Print) 1748-9245 (Online) Journal homepage: http://www.tandfonline.com/loi/yema20

Repair welding technologies for heat recovery

steam generator tubing

D. Gandy, G. Frederick & K. Coleman

To cite this article: D. Gandy, G. Frederick & K. Coleman (2006) Repair welding technologies
for heat recovery steam generator tubing, Energy Materials, 1:2, 127-135, DOI:
10.1179/174892306X99714

To link to this article: http://dx.doi.org/10.1179/174892306X99714

Published online: 20 Nov 2013.

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 Repair welding technologies for heat recovery
steam generator tubing
D. Gandy*, G. Frederick and K. Coleman
A number of premature failures have been observed in heat recovery steam generators, both
along the length of finned tubes and at attachment locations where tubes are joined to the upper
or lower header. Such failures are expensive to correct; furthermore, poor welding access and
repair practices often result in recurrence of the failures with existing welding technology. Two
separate welding technologies under development to address tube failures are described. In the
first, for failures along the length of the tube, damaged sections are severed from the existing tube
and replaced via gas metal arc welding from the inside of the tube. A welding head has been
specifically designed to perform this inside out ‘window weld’ repair. The second technology
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addresses tube to header attachment damage via removal of the existing stub from the inside of a
header and its replacement with a slightly oversized and tapered tube. The two technologies
identified have the potential to give significant improvements in repair of heat recovery steam
generator tube failures by original equipment manufacturers (OEMs) and repair organisations.
Keywords: Repair welding, Finned tubes, Heat recovery steam generators, Heat exchanger tubing

Introduction Background: boiler waterwall window

Tube failures in heat recovery steam generators
(HRSGs) are often the result of high thermal stresses
or thermal shock associated with cyclical plant opera-
tion. Premature failures have been observed both
along the length of finned tubes and at attachment
locations where tubes are joined to the upper or lower
header.
Finned tube repair in HRSGs requires that the welder
gain access to the damaged tube by cutting into the tube
bundle, repair the damaged tube by replacing a short
section and close the access window by rewelding
(replacing short sections of) each tube in the bundle as
he or she works backwards to final tube replacement.
These time consuming and costly repairs have a high
rate of repeat failures as a result of both the welder’s
limited access to the damaged tube and the lack of
welding technologies specific to the task. Moreover,
undamaged tubes have to be severed to gain access to
damaged tubes deep in the tube bundle.
EPRI has recently embarked on a programme to
review existing and commercially available tube welding
equipment and to identify an improved technology for
performing HRSG tube repairs. Previous efforts to
develop an automated window welding device1 have
provided the basis for addressing finned HRSG tubing
repairs.
Department of Materials and Corrosion, EPRI, 1300 West HT Harris Blvd,
Charlotte, NC 28262, USA
*Corresponding author, email gavgandy@epri.com
welding
Replacement of tube sections in boiler waterwall
applications (often referred to as window welding) is
complicated by limited access to the rear or casing side
of the tubes during welding/tube replacement. Limited
access often results in poor weld quality because the
welder cannot see the rear of the tube. As a result, in
2001 EPRI initiated work to develop an automated
welding device to improve weld quality for replacement
waterwall tubing. A patented prototype device was
subsequently assembled.2,3
The novel design utilised prefabricated 16 in
(406 mm) long sections that were prepped on both ends
and contained an access window (Fig. 1). Tube welding
was performed from the inside diameter (inside out) of
the tube, as opposed to conventional outer diameter
welding. Actual welding was performed remotely using a
two piece weld head that could be consistently preplaced
inside of the tube at a specified distance from the weld
joint location. The access window can be completed
using gas metal arc welding (GMAW) or gas tungsten
arc welding (GTAW).
After the prototype was assembled, the device under-
went additional testing at a midwestern power plant.
Three limitations were immediately identified:
(i) the copper tube through which the wire was fed
was not sufficiently rigid to allow repeatable field
welding
(ii) the electronics of the device could be improved
considerably
(iii) the wire feed through was difficult and required
special attention.

ß 2006 Institute of Materials, Minerals and Mining

and W. S. Maney & Son Ltd
Received 8 December 2005; accepted 6 January 2006
DOI 10.1179/174892306X99714 Energy Materials 2006 VOL 1 NO 2 127
 Gandy et al. Repair welding technologies for heat recovery steam generator tubing
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1 Prefabricated tube including inverted weld preps (weld

from ID) and along with window in centre of tube

In spite of these shortcomings, the prototype concept

was considered sound and the device was deemed a
viable option for future tube repairs. The device was
then further developed and refined in collaboration with
Carolina Energy Solutions and its equipment manufac-
turing service arm, Aggressive Equipment Inc. This
involved reconfiguration from a two piece to a single
piece welding head, as is described in detail below.

HRSG repairs
Concurrent with the development of the prototype
welding device, EPRI began to develop material
selection and repair guidelines for HRSGs.2 Tubing
repair was identified as an area requiring better welding
equipment to improve the quality of installation and
repair.
Two types of tube repairs were identified. First,
repairs on tubing away from the upper or lower headers
require welders either to cut their way in and weld their
way out or to plug and abandon the tube. The result is
often poor quality tube welds owing to access limitations
on the rear side of each tube. Mirror welding is
commonly used on the back side of each tube; however,
this repair technique requires a highly skilled welder and
still often results in poor quality. Replacement sections,
in which at least two OD welds are required, are
commonly used. Second, repairs at tubing to header
attachments require a similar approach in cutting in and
welding back out. Another approach often used is to
plug the tube from the inside of the header. This
approach, however, reduces plant efficiency because the
plugged tube is essentially removed from service.
Improved means of addressing these forms of repair
were investigated. For the tube welding application, it
2 Single piece ID tube welder inserted into tube for
welding
was believed the window welding device could, with a
few modifications, be employed for HRSG tube to tube
(replacement of a tube section) welding applications.
During the first half of 2004, improvements in the
window welding device and conversion into a single
piece welder suitable for use in HRSG tubing and boiler
water wall applications were undertaken.
In April 2004, conceptual work began on a method
for repair of tubing to header attachments. A repair
approach was identified and a welding equipment
vendor (Encompass Machines Inc.) selected to develop
a second welding device, which was made available in
early 2006. The repair approach for header to stubtube
damage repair is described below.
ID tube welder
The redesign of the ID tube welder retained the
prefabricated replacement tube (including the preplaced
window, see Fig. 1), along with the GMAW process.
The weld was completed from the inside diameter of the

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 Gandy et al.
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3 Another view of ID tube welder after removal from tube
tube (welds at top and bottom). By reconfiguring the
welding head to a single piece design, the prefabricated
replacement tube length could be reduced to 12–14 in
(300–360 mm). As before, an inverted (inside out) weld
prep was employed.
The single piece welding device shown in Figs. 2 and 3
makes use of alignment collars that are secured within
the replacement tube both above and below the window.
These collars can be sized for 1 in (25 mm) i.d. to 3 in
(75 mm) o.d. tubes, thus offering a wide range of
capabilities regardless of HRSG or water wall tube size.
Once inserted into the tube window, a novel handle
design enables the bottom collar to be centred and
secured (or retracted) in a single motion. The handle is
spring loaded for easy insertion or retraction. This
feature allows a reduced working envelope and enabled
the device to be reduced to a single piece design.
Another feature is height adjustment. A height
indicator enables the user to determine vertical position
of the weld head, thus allowing incremental changes
when necessary to better position the weld torch. Height
Repair welding technologies for heat recovery steam generator tubing
adjustments can be made to ¡0.375 in (9.5 mm) for
multipass welding applications. Gas coverage is pro-
vided for high alloy welding applications via the collet
just below the weld head. Gas coverage can be
maintained from prepurge to post-purge and through-
out the welding process. Rice paper can be placed within
the existing tube to provide a boundary outboard of the
weld region.
Easy use of the ID device issue was actively promoted
in several ways, including minimising the weight,
prefabricating the tubes with standardised windows
and keeping the operation requirements simple.4 The
lighter weight enabled the welder to carry the system
directly to the repair location. The weight of the overall
system was minimised by using a lightweight GMAW
power supply that could be placed within 10 ft (3 m) of
the weld region, a push wire feeder, a compact pendant
board and a lightweight, aluminium based ID weld
head.
The use of the GMAW process and prefabricated
tubes with standardised windows enables the welder to
Energy Materials 2006 VOL 1 NO 2 129
 Gandy et al. Repair welding technologies for heat recovery steam generator tubing
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4 Premachined oval shaped insert used for window
replacement
generate repetitive welds with few changes. Simplicity of
operation was promoted by eliminating vision systems
and by using an up slope and down slope to taper for
appropriate weld conditions, a height adjustment feature
for incremental position changes and an automatic lock
that positions the weld head consistently within the
centre of the window, thus reducing the need for
alignment. Single- or multiple pass welding is readily
achievable.
Another important objective was to keep the cost of
the system low, so that individual plants could afford to
have a window welder on site to address tubing failures
immediately. The ID tube welder was launched publicly
in June 2004.
HRSG tube to tube repairs
HRSG tube to tube weld repairs are somewhat
complicated by the fins around the diameter of the
tubing. Repairs are currently performed with the
shielded metal arc welding (SMAW) process, wherein a
short section of tubing is removed, fins are removed
from the tube ends, the tube is machine prepped for
welding, and an SMAW weld repair is completed.
Limited access to the back side of tubing weldment often
results in poor weld quality. In addition, the welder has
to work through a small enclosure that is encumbered by
the finned tubing that surrounds the tube being repaired.
Only a straight section of tube, which does not (usually)
have fins, is used in the replacement tube.
The ID tube welder approach still requires removal of
the tubing; however, all welding is performed from the
inside of the tube. The new section of tubing, which
contains preps on either end of the tube and a machined
access port at the centre of the tube, is inserted into the
location where the original tube was damaged. Welds
130 Energy Materials 2006 VOL 1 NO 2
5 Failed HRSG tube at header location
are performed (one at the top location and the other at
the bottom) to secure the replacement section of the
tube. Owing to the small thickness of the existing tube,
one pass welding is typically used for both welds.
On completion of the two welds, the final weld to
close and seal the access port is performed. A
premachined oval shaped insert (see Fig. 4) is used for
this replacement, the weld being performed manually by
the welder using the GTAW process. Because the welder
has much better access to the front of the tube
(compared with welding using a mirror on the back
side), high quality closure welds can be produced
consistently.
One goal of this effort was to provide utility
maintenance crews with a readily deployable welding
device that could be quickly mobilised and used. In
addition, plants having premachined tube inserts on the
shelf can substantially reduce time to repair the
damaged tube and rapidly return the plant to service.
HRSG header to tube damage repair
The second form of repair identified2 was tube to header
attachment repair (see tube failure at header location in
Fig. 5). Owing to limited access, this form of repair is
often more difficult to perform than that of conventional
tube repairs; indeed, tube failures are often left in place
and simply plugged. Plugging requires:
(i) removing a window within the header 180u
away from the stub tube attachment location
(ii) machining and inserting a plug into the
damaged tube bore
(iii) welding the plug into place
(iv) reinstalling the window.
The selection of a repair methodology is complicated by
the number of attachment configurations used by
industry. Tube to tube attachment weld designs used
by OEMs include:
(i) partial penetration welds
(ii) full penetration welds
(iii) forged nipples with full penetration welds
(iv) separate nipples and full penetration welds
between nipple and header and to tube.
 Gandy et al. Repair welding technologies for heat recovery steam generator tubing
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6 Example HRSG header attachment configurations

Examples of each of these weld designs are provided in
Fig. 6 and the advantages and disadvantages of each
form of repair have been discussed elsewhere.5 An
approach applicable to all four designs was eventually
developed.
The methodology involves a more pragmatic
approach to HRSG header to tube damage than is
currently used by industry. Repair vendors and OEMs
currently address tube attachment damage from the
outside of the header. This requires cutting past a
number of tubes in a tube bundle, performing the weld
repair from the outside of the tube (often requiring
partial tube replacement) and rewelding all the tubes cut
to gain access. This approach is not only time
consuming and costly but also often results in poor
weld quality owing to the limited access. It also requires
cutting and rewelding multiple tubes that otherwise have
no damage.
The new approach sought to address header to tube
damage from the inside of the header, which involves a
number of steps as follows.
in Fig. 7. The base plate is mounted 180u away and
centred axially along the header from the damaged tube
location.
Once the base plate is in place, the EDM assembly is
mounted to it. An EDM electrode, fabricated to match
the contour and diameter of the header, is inserted into
the EDM assembly and a small plug is removed 180u
from the damaged tube location to provide access to the
inside of the tube. The diameter of the EDM hole is
,0.25 in (0.64 cm) greater than the stub tube diameter
and ,0.5 in (1.3 cm) greater than the damaged tube (see
step 5).
Step 2: align base plate
Once the access hole has been fabricated and the EDM
assembly removed, the next step in the process is to
release the base plate straps and recentre the base plate.

Step 1: EDM access hole in header

The first step in the repair process involves the use of
electro discharge machining (EDM) to open an access
hole in the header. Conventional machining could have
been employed, but it was felt that EDM would
minimise the presence of machine shavings and intro-
duce only minimal particulate (which, hopefully, could
be trapped) into the overall machining process.
The base plate is the platform from which all major
steps are to launched, including EDM, cutting, tube
insertion, welding, etc. The base plate is mounted using
straps that can be secured around the header, as shown 7 Base plate mounted to header using straps

Energy Materials 2006 VOL 1 NO 2 131

 Gandy et al. Repair welding technologies for heat recovery steam generator tubing
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8 Mandrel is inserted through mock-up header (no tube
attached)
This is accomplished using an alignment plug and
centring ring. The realignment step is required to make
certain the entire device (and overall process) is centred
exactly over the damaged tube location. In step 1, the
access hole is roughly placed along the header axis at a
position 180u from the tube location. When working
under limited space conditions, centring the access hole
accurately (step 1) is not easy. Therefore, step 2 allows
for realignment and precise centring of the base plate,
directly over (or under) the damaged tube location.
Once the alignment has been completed and the straps
are resecured, the alignment plug and centring ring can
be removed.
Step 3: mandrel insertion
Next, a mandrel is inserted into the existing damaged
tube. The mandrel is made in two segments, each ,12 in
(30 cm) long (lengths will vary depending on header
diameter). The mandrel is inserted into the tube to
capture the damaged tube so that it does not spring or
get away during the repair process and to create a
centring device on which subsequent cutting operations
will be based. The mandrel is fabricated using a tighten-
up draw bar that expands to secure the grippers (located
at the end of the mandrel) within the tube section. An
example of the actual mandrel is shown in Fig. 8. This
example illustrates the mandrel penetrating the header in
the location where the tube would be. The damaged tube
is (obviously) not in place.
The cutting operations (step 4) once again make use of
the EDM assembly to generate a flat bottom hole inside
the header, directly over the tube location. The flat
bottom hole is necessary to provide a good surface for
132 Energy Materials 2006 VOL 1 NO 2
the dual point machining to be performed in step 4. The
diameter of the flat bottom hole is slightly greater than
the new stub tube, which will be press fitted in step 5.
Therefore, the EDM assembly is reinstalled with a new
flat bottom electrode and the flat bottom hole is
machined. The EDM assembly is then removed.
Step 4: cutting operations
After securing the mandrel, the cutting assembly is
secured to the base plate. The assembly includes a drive
assembly made of a motor and gearing, a two post
design to rigidly secure the cutting assembly to the base
plate, and a cutter shaft assembly (that includes tooling)
mounted over the mandrel. The assembly utilises a
manual drive assembly to raise and lower the cutter
shaft and set tool bits in place. Another feature of the
cutter assembly is that it can be disconnected from the
cutter shaft and pivoted on only one of the two posts.
This enables rapid change out of the cutter shaft
assembly and/or tool bits.
The actual cutting operation is begun by lowering the
cutter shaft/tooling to within ,0.125 in (0.3 cm) from
the flat bottom hole. The equipment is energised and the
cutter shaft/tooling is gradually lowered until contact is
made with the flat bottom hole. Plunge machining
begins at this point and is continued until a new
penetration is made on the opposite side of the header
(180u away from the access hole) and until the
damaged tube is machined to a sufficient depth [usually
1–3 in (2.5–7.6 cm) below the header OD] to facilitate
installation of the new stub tube. Note that by this point,
all of the damage from the existing tube has been
removed.
The next step in the process is disengaging the cutter
shaft/tooling and removing it from the new hole, at
which time a new end prep tool is installed. The new end
prep tool is then relowered with the shaft to complete
the weld preparation on the end of the tube. A dual tool
cutter head is employed for both plunge machining and
final end prep machining. Additional discussion of the
weld joint configuration is provided in step 7.
Step 5: insertion of new stub tube
The overall repair process makes use of a stub tube
(Fig. 9), which is somewhat greater in diameter and is
tapered to coincide with a slightly greater diameter of
the existing tube. Also notable is that a specific joint
geometry is used on the end of the tube, which allows the
stub tube section to slip over the existing tube (see lower
illustration in Fig. 9). Another feature of the stub tube is
that the upper profile of the tube has been fabricated to
match the contour of the inside diameter of the header.
This facilitates header to tube welding, as discussed in
step 9.
Insertion of the tube is accomplished using a tool that
rigidly secures the tube as it is slipped over the mandrel.
The insertion tool has been fabricated so that it
automatically rotates the contoured stub tube to meet
the contour of the inside diameter of the header,
assuring proper alignment each time; and enables the
stub tube to be press fitted into place within the header
penetration and over the existing end prepped tube. A
photograph of a stub tube pressed into place through the
header and over the existing tube is shown in Fig. 10.
 Gandy et al.
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9 Tapered stub tube employed to join existing tube to
header
Step 6: preheating
At this point in the process, all machining operations
have been completed and the stub tube is in place to
begin the preheating, welding and post weld heat
treatment (PWHT) operations. Note that the entire
repair process involves P/T91 header, tubing and a stub
tube. P/T91 is a material that must be handled with
utmost care to avoid future damage.
Before beginning welding operations, P91 materials
will require preheating to 204uC (400uF). A preheating
methodology was identified in early 2006 and demon-
strated via an HRSG mockup.
Step 7: welding header to stub tube
Two welds must be performed to install the stub tube: to
secure the stub tube to the header and (in step 8) to the
existing finned tube. As discussed in step 5, the new stub
tube is press fitted, resulting in a tight fit with the header,
and is also pressed into place so that it fits over the
existing stub tube to keep it from moving. The stub tube
itself is contoured and prepared for welding before its
insertion into the header.
Header to stubtube (HST) welding makes use of a gas
tungsten arc profile weld head that has been specially
designed for this welding operation. Profile welding of
abnormal geometries (such as saddle welds and elbows)
is difficult and is normally conducted using manual
welding processes. Though manual welding was con-
sidered for the HST weld, the repair team believed the
process must be automated owing to the limited space
Repair welding technologies for heat recovery steam generator tubing
10 Stub tube shown in final position after press fitted
into place
requirements. The welding device must be capable of
both attaching directly to the base plate and extending
down into the header to address contour type welds.
Figure 11 demonstrates the actual welding in process
from the inside diameter of a header.
Step 8: tube to tube welding
The tube to tube weld is next performed. As described
above, the new stub tube is configured to slide over the
outer diameter of the existing tube, to prevent the tube
from swinging or moving, before and during the welding
process, and to provide backing so that an open root
type weld will not be required.
The present configuration makes use of a consumable
insert that is tacked inside the stub tube and slid over the
existing tube. A completed weld that has been cross-
sectioned and polished is shown in Fig. 12.
Step 9: closure weld (replace access hole)
Before completing the final, PWHT of the previous two
welds (steps 7 and 8), it is necessary to complete the
closure weld that replaces the access hole generated in
step 1 of the repair process. The closure weld will also
require PWHT, so all three welds should be heat treated
concurrently.
The closure weld employs the plug that was removed
to generate the access hole during the EDM process
Energy Materials 2006 VOL 1 NO 2 133
 Gandy et al. Repair welding technologies for heat recovery steam generator tubing

The weld build-up should be accomplished outside the

HRSG in a controlled area where the plug can be
effectively GTAW welded using a B9 type filler. The
build-up should be sufficient to allow a 30u weld prep to
be machined around its diameter to match the 30u weld
prep required for the access hole. The latter weld prep
could be performed before removing the weld base plate
by simply reinserting the tooling device.
Once the two weld preps (plug and access hole) have
been completed, the plug can be reinserted into the
header. This can be accomplished by tacking the plug into
place, continuing the welding preheat on the overall
header, and completing the final weld to secure the plug.
This weld should be straight forward, easily accessible
and easy to address with manual GTAW.

Step 10: post weld heat treatment

The final step in the overall repair process is to complete
the PWHT of all three welds and the surrounding repair
region. As mentioned in step 6 (welding preheat), the
preheating and PWHT methodologies were developed in
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early 2006 using an HRSG mockup.

11 Welding stub tube to header in process, as shown
from header inside diameter
(step 1), to minimise costs and avoid potential delays.
The plug diameter must be built up slightly (via welding)
to prepare the plug for reinsertion, because EDM
removes material at a thickness equivalent to the
thickness of the EDM electrode.
Summary and conclusions
Tube damage and attachment damage have resulted in a
considerable number of failures in HRSG equipment.
This has led to demand for less obtrusive, more
repeatable welding methodologies to perform these two
forms of repair. Equipment capable of implementing such

12 Cross-sectional view of completed tube to tube weldment

134 Energy Materials 2006 VOL 1 NO 2

 Gandy et al.
methodologies would benefit power plant personnel,
repair vendors, installers and OEMs. Equipment design
and development during 2004 and 2005 has achieved
significant progress towards this objective:
1. A patented ID tube welder has been prototyped,
developed and commercialised for performing both water
wall window welds and HRSG tube to tube weld repairs.
2. The ID Tube Welder significantly reduces the time
required to perform window welds or HRSG tube to
tube welds compared with conventional SMAW type
repairs. Furthermore, it provides power plants with a
consistent, rapidly deployable method to perform
repairs and minimise welder error.
3. A tube to header attachment repair methodology
has been identified to address all four attachments now
offered by OEMs. Equipment development has been
completed for all machining steps involved in the repair
process (EDM and plunge type cutting). Development
has also been completed for the two welding steps where
a new stub tube is attached to the header and a tube to
tube weld is completed between the existing tube and the
new stub tube. The new repair technology for attach-
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ment welds was made available in February 2006.
Acknowledgements
The authors thank R. Bryant, R. Phillips, L. Tellone and
D. Thorton from Carolina Energy Solutions/Aggressive
Repair welding technologies for heat recovery steam generator tubing
Equipment for their input, insight and development
capabilities in bringing the tube to tube welder to
market. Thanks are also expressed to members of the
EPRI Boiler Life & Availability program (P63), and to
R. Tilley who manages this programme for funding and
pursuing advanced welding technologies for water wall
applications that eventually led to the development of
the ID tube welder. The authors would also like to thank
K. Spencer, P. Nusbaum and K. Brazzell of Encompass
Machines for their assistance in bringing the HST repair
device to market. The collaboration of Specialty
Welding and Machine as the primary contractor in
development of the boiler water wall window welding
device and of Mannings USA in development of PWHT
methodologies for finned tube repair is gratefully
acknowledged.
References
1. EPRI: ‘Boiler life and availability improvement’, Program 63, Palo
Alto, CA, USA, available at: www.epri.com/portfolio.
2. ‘HRSG material selection and repair guidelines’, Report 1004875,
EPRI, Palo Alto, CA, 2004.
3. ‘Method and apparatus and prefabricated replacement tube for
localized waterwall repair’, US Patent 6,596,957 B2, EPRI, Palo
Alto, CA, 2003.
4. Aggressive Equipment, Inc. web site photographs, available at:
http://www.aggressive-equipment.com/new/idtubeweld.html.
5. ‘Delivering high reliability heat recovery steam generators’, Report
1004240, EPRI, Palo Alto, CA, 2003.
Energy Materials 2006 VOL 1 NO 2 135