HEAT-RECOVERY STEAM GENERATORS

Water-chemistry, outagemaintenance best practices highlight Steam Plant Workshop

s experience builds with combined-cycle and cogeneration plants, suppliers are striving to better integrate the steam cycle with the gas-turbine cycle, while users are working to improve their operations and maintenance (O&M) practices. Advances made by both parties were presented at a Steam Plant Workshop in November 2006, conducted by the HRSG Users Group and co-located with PowerGen International (Sidebar). Advancements discussed at the meeting include switching to all-volatile treatment to avoid phosphate hideout, minimizing the use of oxygen scavengers to reduce flow-accelerated corrosion, and installing on-line instruments to measure metal-oxide transport. The maintenance presentations on the second day of the workshop covered methods to mitigate cold-end corrosion in the HRSG, techniques to maximize the service life of SCR catalysts, and a programmatic approach to conducting corrosion surveys.

Boiler-water/feedwater chemistry
Considering their relatively short operating history, heat-recovery steam generators (HRSGs) in combinedcycle/cogen service have experienced unexpectedly high failure rates. While some of the failure mechanisms are strictly mechanical, many have a significant water-chemistry component. Thats why, according to Bob Anderson, principal, Competitive Power Resources Corp, Palmetto, Fla, and chairman, HRSG Users Group, the first day of the Steam Plant Workshop was devoted to water chemistry. AVT meets HRSG. Jim Witherow, executive chemist, Scientech LLC, Clearwater, Fla, delivered the opening presentation, which was focused on all-volatile treatment (AVT) of boiler water. More and more HRSG users are switching from a solidsbased phosphate program, Witherow asserted, to an AVT program, which relies on volatile amines to elevate the pH to the optimum level for corrosion control. Recall that low pH will lead to rapid acidic corrosion and also may cause hydrogen damage in carbon steel. Excessively alkaline conditions can cause caustic corrosion. The sweet spot is a mildly alkaline environmentpH in the range of 9.0 to 10.0, depending on boiler specificsthat will produce minimal corrosion and minimal corrosion-product transport. For years, AVT has been successfully applied at coal-fired plants with 2600-psig drum boilers, and at all plants with once-through steam generators. As Witherow made clear, once-through units simply cannot tolerate any solids in their steam generators, so phosphate programs were never a choice. Most HRSG users, however, have relied on a phosphate program for their drum-type HRSGs, which typically operate below 2600 psig. Phosphate programs are applicable to a wide range of boiler pressures, they provide buffering in the event of contaminant ingress, and they help

HRSG Users Group planning 2007 Workshop

The HRSG Users Group, a professional association open to all combined-cycle/cogen professionals, typically conducts two educational events per year: the Annual Conference & Exposition in the spring, and a Technical Workshop in late fall. Chairman Bob Anderson recently announced that the groups 2007 Technical Workshop will be held December 11-13 and be co-located with PowerGen International at the Ernest N Morial Convention Center in New Orleans. Stay tuned to the COMBINED CYCLE Journal and the groups website (www.HRSGusers.org) for more detail as the agenda develops.
COMBINED CYCLE Journal, First Quarter 2007

remove contaminants by precipitating them into a sludge that easily can be eliminated by blowdown. Given such advantages, why are HRSG users switching to AVT? Primarily to avoid the wild swings in pH and cation conductivity that stem from phosphate hideout, Witherow reported. Phosphate hideout is a collective term for a number of processes that remove phosphate from the bulk boiler water at high loads, then release some of it back into the water when the load drops or the plant is cycled off-line. Net result is a significant fluctuation in pH. Hideout has always been an issue for boiler operators using phosphate treatment, but it has grown in importance in the combined-cycle/cogen community as HRSG steam pressures have increased to more than 1400 psig, and as plants have been forced to cycle more frequently. As Witherow described it, there are two distinct AVT programs, differentiated by a parameter called oxidationreduction potential (ORP). Systems containing mixed metallurgy (copper and steel) must operate in a reducing environment (at an ORP of 350 to 300 mV), in order to control copper corrosion. To achieve this environment, these plants must inject a reducing agent, Witherow said, hence their program is known as AVT(R). By contrast, systems that contain all-ferrous components should operate in an oxidizing environment (ORP equals +100 mV); their program is known as AVT(O). The oxidizing programwhich uses no reducing agentsis preferred for all-ferrous systems, Witherow reported, because reducing agents have been found to be a culprit in single-phase flow-accelerated corrosion (FAC) occurring in lowpressure evaporators (Fig 1). Reducing agents also are known as oxygen scavengers, so when chemistry authorities like Witherow recommend eliminating their use, they also are saying its acceptable to allow some level of dissolved oxygen in your steam system. This assertion often ignites a firestorm of protest among seasoned operators,
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1. Many HRSG users are switching from phosphates to an all-volatile treatment (AVT) program for their boiler water. Plants with all-ferrous systems that are making the switch should not feed reducing agents, most specialists agree, because theyve been found to be a culprit in single-phase FAC because for decades they were taught that dissolved oxygen must be completely eliminated from the feedwater in order to control oxygen pitting. More recent experience, most of it chronicled by the Electric Power Research Institute, Palo Alto, Calif, over the past decade, shows that it is not necessary to drive dissolved-oxygen all the way to zero; that levels of 1-10 ppb are sufficiently low to control pitting, while the elimination of oxygen scavengers controls FAC. Ammonia is the most commonly applied pH-control agent in a boilerwater AVT program, while hydrazine is the most commonly applied reducing agent. Caution is needed here, With46

erow emphasized, because hydrazine is listed as a known or suspected carcinogen, and no approved respirator exists for handling its spills. The use of hydrazine may require monitoring of personnel exposure, using timeweighted averages. A reducing agent thats not on the carcinogen list and is a viable alternative is diethylhydroxylamineusually referred to as DEHA. Another way to eliminate phosphate hideout is to switch to a program known as caustic treatment. To discuss this option, Dr Geoff Bignold, director, GJB Chemistry for Power Ltd , Ashtead, Surrey, flew in from his UK office, where the program enjoys wider acceptance in both convention-

al boilers and HRSGs, compared to 8/28/06 6:48:58 PM America. Like phosphate treatment, caustic treatment is a solids-based program. The addition of a small amount of sodium hydroxide (NaOH) buffers the boiler-water pH and allows for a higher level of anionic contamination than with AVT programs. The reason most North American plants avoid the program is the risk of caustic cracking caused by an excessive concentration of NaOH. According to Bignold, this concern stems from catastrophic failures in the early days of riveted-drum boilers, which were much more susceptible to caustic cracking than todays drums. Reason: The rivets allowed minor leak paths to form, and as steam flashed off through those paths it left exceptionally high concentrations of NaOH in localized spots (Fig 2). Failure by caustic cracking was almost inevitable in these locations. Bignold pointed out that for a modern steam generator operating above about 1400 psig, NaOH chemistry has proved easier to control than phosphate chemistry, with more stable pH values and no concerns about phosphate hideout. Compared to AVT, caustic treatment provides more protection against contaminants, and maintains pH at elevated temperatures much better than ammonia or amines do. One big caution, he said, is that

Scientech LLC

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you must avoid overdosing. Another big concern: If the boiler drum is susceptible to carryover, then caustic treatment presents the risk of forming highly alkaline deposits in superheaters, reheaters, and steam turbines. Bignold wrapped up his presentation with two case histories where caustic treatment had successfully been applied to solve chemistry problems in HRSGsone caused by phosphate treatment, the other by AVT.

Emerging jet flashes to steam, leaving concentrated or molten NaOH Small leak around rivet

NaOH-dosed boiler water

Dont sell your phosphate stocks

Given the workshops coverage of AVT and caustic treatment, you might think that phosphate programs are going away soon. Youd be wrong. In fact, most HRSG users in North America still rely on phosphate, reported Stephen Shulder, chemistry consultant, Constellation Energy Group, Baltimore, Md, and many of them always will need to. One reason: Phosphate is the program-of-choice for plants with high levels of total dissolved solids (TDS) in the condenser water. For these plants, condenser leakswith their ingress of acidic-forming cooling watercould cause a rapid and damaging pH depression in the boiler circuits. The capabilities of phosphateto buffer contaminant ingress and to remove

2. Caustic treatment is another waterchemistry option that eliminates the issue of phosphate hideout. Reluctance to use this option stems from catastrophic failures in the early days of riveted-drum boilers, which were prone to caustic cracking contaminants by precipitating them into a sludge for blowdowncan prevent this major upset from snowballing into catastrophic damage. Another reason that phosphate programs remain popular with HRSG users: To successfully apply AVT, the plant must have high-quality feedwater, typically attainable only if the condensate system is equipped with in-line demineralizers (also called condensate polishers). Plants with lower-quality feedwaterand scarce

capital funding to install condensate polishersare likely better off with a phosphate program. Shulder explained that three forms of phosphate historically have been used in the power industry: tri-sodium phosphate (Na3PO4), di-sodium phosphate (Na2HPO4), and mono-sodium phosphate (NaH2PO4). Today, the use of mono- or di-sodium phosphate is highly discouraged, and only tri-sodium phosphate should be considered, he stated emphatically. Plants that followed mono- or disodium phosphate treatment experienced serious problems with acid-phosphate corrosion, as a result of chasing phosphate hideout. As Witherow reported in his opening session, phosphate hideout is still a problem, even for plants using tri-sodium phosphate, but it is less so than under mono- or disodium phosphate regimes. Shulder cautioned that the control limits for phosphate concentration, pH, and specific conductivity of boiler water are highly dependent on site-specific factors. Chief among them: feedwater quality. For three different levels of feedwater cation conductivity, Shulder discussed appropriate boiler-water control limits (Table). He concluded his presentation by listing keys to a successful phosphate-treatment program for HRSG users, among them: n On-line monitoring of critical
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COMBINED CYCLE Journal, First Quarter 2007

HEAT-RECOVERY STEAM GENERATORS

16 14 12 Amine product, ppm 10 8 6 4 2 0 8.5 8.6 8.7 8.8 8.9 9.0 9.1 9.2 9.3 Condensate/feedwater pH 9.4 9.5 9.6 Morpholine 100% Ethanolamine 100% Cyclohexylamine 100% Methoxypropylamine (MOPA) 100% Ammonia 100%

3. The best feedwater treatment for each plant depends on the chemicals basicitythe amount of pH increase per amount of chemical injectedand its volatilitythe fraction of the chemical that goes into the steam as it boils, or remains in the steam as it condenses
n Rapid response to chemistry excur-

has a higher basicity than cyclohexylamine (Fig 3). In practice, these four amines often are blended together to obtain the optimum combination of basicity and volatility. Choosing the right amine blend depends on your plant-specific answers to such questions as: n How much of the blend do you need to add to achieve the desired pH in the low-pressure drum and piping? n Will the blend have a measurable effect on the pH in the high-pressure evaporator? n What is the blends effect on cation conductivity? n What are its effects on other equipment throughout the steam plant?

The final presentation on Day One of the Steam Plant Workshop discussed a new on-line instrument for measuring corrosion-product transport. Authors were L Joseph Hancock and Richard A Breckenridge of Arizona Public Service Co, Phoenix, and Robert L Bryant and John W Clark of Chemtrac Systems Inc, Norcross, Ga. Corrosion products include all metal oxides that are formed in the corrosion Feeding the feedwater process. In modern HRSGs, most of Its often said that to achieve an the corrosion-product content is iron, effective boiler-water treatment prothough some units may have copper gram, you must start with an effecand nickel in the condenser or preheattive feedwater treatment program. er sections. The amount of corrosion Thats because its far easier to preproducts present in the water/steam vent corrosive species from entering circuits is an important diagnostic the boiler than it is to remove or remeparameter for cycle chemistry. For diate them once theyre present. This example, its an indicator of the scale maxim wasnt lost on the planners that is accumulating on HRSG tubes, of the Steam Plant Workshop, who as well as of the rate of FAC occurring invited David Daniels, senior consultin the system. Most important, meaing scientist, Mechanical & Materials suring the corrosion-product transport Engineering, Austin, Tex, assesses the effectiveto discuss the finer points of Phosphate chemistry guidelines* ness of a steam plants feedwater chemistry. overall chemistry proTo elevate the feedwater gram. Feedwater cation Boiler-water chemistry pHand thereby prevent As Breckenridge conductivity corrosionin combinedexplained, the tra Specific Conductivity < 20 S/cm cycle/cogen plants, volatile ditional methods for < 0.2 S/cm pH = 9.0-9.8 chemicals in the amine fammonitoring metalPO4 = 1 to 3 mg/L ily are used almost excluoxide transport include Specific Conductivity = 20-40 S/cm sively, Daniels reported. millipore pads, ion0.2 to 0.5 S/cm pH = 9.0 to 9.9 Reason: Spray water for the exchange columns, PO4 = 2 to 6 mg/L attemperators (also called atomic absorption Specific Conductivity > 40 S/cm desuperheaters) typically spectroscopy, and X> 0.5 S/cm pH = 9.1 to 10.1 is taken from the feedwaray diffraction. All of PO = 2 to 10 mg/L 4 ter system, and it would be these require manual highly undesirable to inject *Extracted from ALSTOM Power Boilers, 2006 grab sampling and dissolved solids directly into cumbersome analysis the steam. Note: For this same reason, ed as feedwater alternatives include in the lab. volatile treatment also must be used cyclohexylamine, morpholine, ethRecently, Chemtrac introduced an in the low-pressure evaporator sec- anolamine, methoxypropylamine on-line particle counter that promises tion of an HRSG if it supplies water (MOPA), and diethylaminoethanol to measure metal-oxide transport in a to attemperators, as it does in some (DEAE). Both morpholine and cyclo- continuous and convenient manner. combined-cycle designs. hexylamine, for example, have a lower The counter uses a laser diode and a To select the right feedwater chem- volatility than ammonia; morpholine detector to measure particles of the sions. n Proper match of phosphate level to drum pressure and feedwater quality. n Correcting the pH readings for the contribution from ammonia. n Consistently maintaining corrected pH greater than 9.0.
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parameters.

ical treatment for your plant, Daniels recommended you look at each chemicals basicitythe amount of pH increase per amount of chemical injectedand its volatilitythe fraction of the chemical that goes into the steam as it boils, or remains in the steam as it condenses. Low-volatility amines condense at relatively high temperatures and pressures; high-volatility amines stay in the vapor state until the pressure and temperature are relatively low. Ammonia is the feedwater chemical-of-choice in all-ferrous systems, Daniels said, because of its high basicity and low cost. But a major drawback is its high volatility. At the deck-plate level, this means that at low temperatures ammonia remains in a vapor condition longer than the other amines, therefore it can more easily get carried out of the system by vacuum pumps and steam-jet air ejectors. Other amines that Daniels list-

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specific size of interestfrom 2 to 100 vanized structural steel at the site, on microns in diameter (Fig 4). Arizona top of the high-pressure steam drum, Public Service Co currently is using and all over the top sections of the the Chemtrac counter for metal-oxide HRSGs. Basically, we were seeing measurement, and is gathering data rust anywhere there was a horizontal, For over 39 years, the Olympus Corporation focused its technological advancements to support the on its effectiveness. Watch for results flat surface, Emmons said. Within the Power-Gen increasing demands and growing requirements of the borescope inspector. to be discussed at future HRSG Users The HRSG Users Group devoted the Initially, the observations proinspectors have identified three criteria that have become theno core theof Olympus RVI industry, Group events. secondkey day of its Steam Plant Workduced real of sense urgency, but shop to maintenance tasks that users then other signs of trouble surfaced. new product development standards. often encounter during a scheduled For example, the HRSG casing liners outage. Kaye Emmons, plant engi- began to show damage during outneer, Chehalis Power Generating age inspections, and rust spots were Shortening the Seeing the Wash, opened the day noticed Durability, LLC, Chehalis, on a neighboring facilitys roof Learning Curve Early-Warning Indicators 24/7 Reliability with a presentation titled Cold-End and on its manufactured products. Laser diode Detector Corrosion: Causes and Cures. The spots seemed to appear after each Chehalis station two powerplant startup. Rust flakes EarlyThe detection is the key comprises to preventing borescope can bealso their By designing easy-to-use videoscopes, The inspectors dual-fueled GE 7FA gas turbines, two were appearing on employees vehicles failures that result in very costly outages most important tool for performing timely, new inspectors can become skilled, triple-pressure, reheat HRSGs manu- in the plants parking lot. In addition, and downtime. In order to identify qualified borescope inspectors in a accurate and on reliable turbine assessfactured by Doosan Heavy Industries backpressure the operating gas damage in the early stages, IPLEX much shorter time period. With IPLEX ments. IPLEX Videoscopes feature a & Construction Co (South Korea), and turbines began to climb. 1 @ 3 microns Videoscopes are designed with optimized Videoscope features such as remote durable insertion tube, winding one Alstom STF20C steam turbine. Causes. By this point, it wasstorage clear 2 @ 1 micron optical systems, high quality lens systems reel significant and rugged enclosure designed to controls with one-touch access to menu Commissioned in 2003, the station that gas-side corrosion was and image processing that like advanced many combined-cycle plants these occurring invideoscope the cold endlifetime, of the HRSGs, functions and an intuitive software interextend the provide delivers the been image quality necessary to dayshas dispatched off-line for particularly during off-line and face, inspectors can quickly learn to use for safe, clean storage ofperiods, the owners detect small indicators potential failures. significant periods. of Its average capac- the resulting corrosion were investment and reduce products the overall cost a new scope and concentrate their time With early identification of was failure sympity factor for 2004-2005 approxigetting blown out of the stack during on developing the intuition to identify of ownership resulting in the most mately 52%, Emmons reported, a stat subsequent startups (Fig 5). Before 4. New on-line particle counter toms, a plant manager can plan for repairs durable and reliable tool for borescope symptoms critical failures and other that than helps explain the cold-end corro- Emmons and her teammates could start offers a of way to measure metal-oxide rather react to failuresthus greatly inspections. damage indicators. sion Chehalis correcting the problem, they had to transport in your steam/water circuits, reducing overall experienced. maintenance costs. First indications of a corrosion prob- understand its causes. in a continuous and more convenient lem were rust spots on the roof of the Because Chehalis is a duel-fueled manner than traditional grab sampling turbine building, on much of the gal- plant, sulfur was one potential culprit. and laboratory analysis

Day Two: OutageMeeting an industrys needs through innovation maintenance best practices

Chemtrac Systems Inc

COMBINED CYCLE Journal, First Quarter 2007

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HEAT-RECOVERY STEAM GENERATORS

But other than a short run on liquid fuel during commissioning, the plant had fired only pipeline-quality natural gas, so sulfur seemed an unlikely cause at first glance. Closer examination, however, revealed that pipeline natural gas in western Washington had been running about 20 times more sulfur than gas in the rest of the US pipeline system. Sulfur content averaged between 20 and 30 ppm in 2006, Emmons reported, and was measured as high as 60 ppm in May of that year. The regulatory limit is just over 15 ppm sulfur. Emmons next looked to determine if the stack conditions were allowing sulfuric acid (H 2SO 4) to form. She understood that if the flue-gas temperature falls below the acid dewpoint, you will begin condensing acid out of the flue gas, thereby creating a destructive acid mist. However, Emmons discovered that determining a specific stacks exact acid dewpoint is quite challenging. First, there is a lack of confidence in the total sulfur measurement of the natural gas, as well as in the test methods for sulfuric acid in flue gas. On-line or portable acid dewpoint analyzers are not believed to be accurate at low levels of sulfur. In addition, ammonia from the plants SCR system interferes with the usual, EPA-approved method of H2SO4 analysis. Ultimately, Emmons estimated the sulfuric acid dewpoint to be between 150F and 200F, depending on the amount of sulfur in fuel and the amount of SO3 formed, and initiated actions to keep flue-gas temperatures above that range. Yet another potential culprit at Chehalis was humidity in the ambient air, coupled with its extended shutdown periods and a lack of stack damper. As Emmons explained, during outage periods the stack-effect draws large amounts of humid air through the HRSG, causing moisture to collect on cold, carbon-steel surfaces. The phenomenon is referred to as off-line corrosion, and it can affect steam plants that sit idle for extended periods of timesuch as combinedcycle plants that have been dispatched at low capacity factors. In North America, HRSGs tend to sit idle more frequently during the fall and spring, which also coincide with wetter weather, increasing the potential for off-line corrosion. Rainwater and humidity entering through an open stack or through leaking roofcasing pipe penetrations help drive the corrosion process. HRSGs that have SCRs and experience ammonia salt deposits on the tubesChehalis fits right into this category, tooare
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5. Cold-end corrosion in an HRSG can be so severe that rust particulates blow out of the stack during plant startups. Aggressive action by plant personnel and suppliers resolved the problem at this site particularly vulnerable to off-line corrosion. Ammonia salts are capable of absorbing moisture from the atmosphere, so they will become moist over time. When the salts become moist, they turn acidic, accelerating corrosion. Cures. With causes understood, Emmons and her teammates began the cures. To address the sulfur in the fuel, they investigated the options and solicited bids for on-site sulfur-scrubbing equipment. Installation of the scrubbers currently is underway. To further inhibit the formation of sulfuric acid in the flue gas, Chehalis increased the operating temperature of its low-pressure (LP) economizer. This required replacement of the original recirculation pump, installation of an economizer bypass control valve, and changes in operating procedures to enable heat-up of the LP economizer during each startup and before each shutdown. The revised operating procedures also postpone startups, when its feasible to do so, if the wind direction will send corrosion products toward neighboring facilities. To combat the off-line corrosion, Chehalis is retrofitting a remote-controlled, safety-interlocked, four-louver stack damper, as well as a regenerative desiccant-type dehumidifier, on each unit. Together, the equipment should keep gas-side components dry during the plants frequent and long shutdown periods. Additionally, plant personnel increased the frequency and scope of their gas-side cleaning program during outages. For example, they began opening, inspecting, and sweeping out solids during any shutdown that was long enough to cool off the HRSG. They also conducted extensive cleaning of the tube bundles, using a variety of techniques over a period of time.

Multiple efforts were required because the HRSG configuration proved difficult to clean. In the LP economizer, there are 14 rows of 84 tubes each, measuring roughly 25 ft wide and almost 60 ft tall. Total surface area of the tubes alonenot counting the finsis over 27,000 sq ft, Emmons calculated. To start the daunting cleaning task, a contractor was hired to conduct CO2 blasting. But this technique proved effective only on the leading one or two rows in each tube bundle. It also was expensive, Emmons pointed out, at a cost exceeding $300,000 for the cleaning of three tubesheet faces in each HRSG (both sides of the LP economizer, and the downstream side of the LP evaporator). Next, the plant tried washing with high-pressure, high-pH water. This proved more effective than the CO2 pellets, but disadvantages included the large volumes of wastewater and sludge that required disposal, and the risk of causing yet more corrosion in the HRSG from wetted surfaces and standing water. After its first water wash, Emmons noticed that the backpressure on the gas turbines had actually gotten worse. Using a borescope, engineers assessed the condition of the interior of the tube bank, and found that the water had penetrated only about the first five rows on either side of the bundle. We felt that this cleaning method had the potential to push more solids into the center rows, and also to collect precipitated solids from super-saturated cleaning water on the dirty tube rows, Emmons explained (Fig 6). Finally, plant personnel tried air lancing to remove the stubborn deposits, and this proved most successful at reducing the gas-turbine backpressure. This was a low-cost, relatively convenient task, because it could be done with in-house personnel and a rented air compressor. Emmons cautions that air lancing, by itself, may not have been as effective. At Chehalis, it was done only after CO2 blasting and extended water washing had already been conducted.

Chehalis Power Generating LLC

Safeguarding SCRs
Another maintenance-focused presentation at was delivered by Michael Stockstad, environmental manager, New York Power Authority (NYPA), the nations largest state-owned power producer, based in White Plains, NY. Stockstads topic: selective catalytic reduction (SCR) systems. In combined-cycle/cogen plants firing natural gas, SCR service life can
COMBINED CYCLE Journal, First Quarter 2007

be expected to reach 10 years or more, with few O&M headaches. However, problems occasionally can be encountered, and when they are, they can be serious. NYPA, Stockstad explained, had 11 units that suffered severe catalyst degradation during their first 1500 hours of operation. In response, NYPA became part of an informal working group with approximately 50 other users, intent on studying and resolving the issues. For starters, the group learned that sufficient quantity of the catalystin terms of surface area of the reactive substancemust be installed during initial plant construction. The group also learned the details of catalystdeterioration mechanismssuch as thermal sintering, liquid contact, fouling, and poisoning. The long list of potential poisons that HRSG users need to beware of include particulates, sulfur, ammonia-sulfur compounds, sodium, vanadium, chromium, and silica. To detect fouling or poisoning, the catalyst must be routinely sampled during plant outages, Stockstad explained. He recommended sampling even prior to first fire of the gas turbine, to establish each units baseline. After that, your sampling frequency should be based on emissions trends, expected service life, and operating conditions. Cycling plants might want

Clean exterior tube

Row-3 tube, still fairly clean

Farther into the tube bundle, deposits become prominent

Nearly impenetrable deposits near center of tube bundle

6. Gas-side tube cleaning may require several attempts using several technologies. CO2 blasting did an excellent job on the first few rows (far left), but borescopic inspection showed that deposits were not removed from tubes deeper in the bundle. A combination of washing with high-pH water and air lancing was needed to clean the heavy deposits at the center of the tube bundle (far right) to sample more frequentlyin terms of operating hoursthan baseload units; dual-fueled units should sample more frequently than those firing only natural gas. When samples are extracted, Stockstad said, be sure to record operating hours of the unit, and for each sample its location, direction of exhaust-gas flow, and front/back faces. An effective sampling program will identify the rate of decay of each catalyst, enabling you, in most cases, to replace the material before you exceed emissions limits. If your SCR is prematurely causing you to exceed limits, you need to investigate all of the potential catalyst-deterioration mechanisms. But the catalyst is only one component in an overall emissions-control system, Stockstad emphasized; therefore all other components should be investigated as well. For example, the ammonia injection may be faulty. Real-life problems that Stockstad discussed include low-quality ammonia delivered by the supplier, contamination of the ammonia during on loading or injection, improper configuration or tuning of the ammoniainjection grid, and incorrect ammonia temperature. Another component in the overall
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Chehalis Power Generating LLC

HEAT-RECOVERY STEAM GENERATORS

From this inclusive list, you can rule-out specific systems and components based on their as-built design and operating environment. After compiling your susceptibility list, you can prioritize the components in terms of risk, and even pinpoint the more vulnerable locations within individual components. At these locations, nondestructive examination (NDE) tools are used to conduct screening examinations. They help narrow down the list of sites requiring the most comprehensive tests, minimizing overall survey costs. Screening tools that Gressler and his colleagues use include pulsed eddycurrent testing, digital radiography, and a newer form of ultrasonic testing (UT) known as long-range guidedwave UT. The latter can scan hundreds of feet of piping from a single location, with minimal removal of pipe insulation. Finally, armed with the results of the screening tests, very detailed, manual wall-thickness mapping is conducted on the most vulnerable sites. This requires the removal of thermal insulation from each site, and measurement of remaining wall thickness via manual UT. Because of the localized nature of FAC, the manual UT readings must be taken on a repeatable, closely spaced grid, which is painted on the outer surface of the target component (Fig 8). In total, wall-thickness mapping is a very time- and labor-intensive process, but one that must be conducted if the FAC survey is to provide reliable results. Even if your FAC survey finds little damage, and wall thicknesses remaining above the Code-mandated minimums, your work is not over, Gressler advised. Your survey data should be plugged into predictive engineering models that will forecast future wall thicknesses, enabling you to schedule your next FAC survey, consider changes to your chemistry program, and plan material replacements long before pipe walls reach dangerous levels of thinning. Ounce of prevention, pound of cure. While Gressler addressed the monitoring of FAC, he was quick to point out that all HRSG users should have a two-pronged approach to the failure mechanismmonitoring of the damage and minimization of the underlying corrosion mechanism. Minimization can only be accomplished, he affirmed, through the strict control of boiler water and feedwater chemistry. Thus, the Steam Plant Workshop was brought full circle, with the second days focus on outage maintenance directly tied to the first days focus on water treatment. CCJ
COMBINED CYCLE Journal, First Quarter 2007

New York Power Authority

7. Leakage around catalyst modules (left, center) or between individual bricks within a module (right) will allow unconverted exhaust gas to bypass the SCR, sending overall NOx emissions higher. Tracking of emissions levels versus ammonia consumption, and thorough inspections during outages will ward off trouble SCR system is the exhaust gas flowing through the catalyst. Stockstad asked: Are the exhaust-gas constituents as designed? What are its temperature, velocity, and distribution characteristics? Is exhaust gas leaking around catalyst modules or in between the individual catalyst bricks (Fig 7)? Any of these variables can cause your SCR performance to drop, and your emissions to soar. Best way to monitor these problems is with a thorough HRSG inspection during major plant outages. financial resources to make safety a reality. This includes the funding of qualified contractors, as well as the approval of extra time in the outage schedule to conduct the survey. Theres greater value in doing a thorough examination of a few high-risk components, he emphasized, than in doing superficial spot-checks on many random locations. Once the funding and scheduling are in place, Gressler recommended you move to a detailed engineering review that identifies the susceptible components specific to your plant. Initially, all systems made of carbon or low-alloy steel containing flowing water or wet steam should be considered susceptible to FAC.

Mandated: FAC surveys

Another task that HRSG users can encounter during a major outage is conducting an FAC survey. Steve Gressler, senior associate, Structural Integrity Associates Inc, Silver Springs, Md, addressed how to plan and execute the task. For California plants, an FAC survey is now a legal requirement, mandated by the Public Utility Commissions General Order 167, adopted in 2004. For plants in other US states, an FAC survey is strongly recommended by the Occupational Safety and Health Administration (OSHA), in its Hazard Information Bulletin dated Oct 31, 1996. And for any steam plant located anywhere in the world, an FAC survey is no doubt an industry best practice. Thats because FAC, which causes internal, localized thinning of pipe walls, is a dangerous and unseen failure mechanism. It has led to many sudden, catastrophic failures of pipes, numerous personnel injuries, and multiple deaths of powerplant workers. A properly implemented FAC survey, Gressler pointed out, begins at the top, with a corporate commitment to safety. The best power producers put that commitment in writing, he said, and authorize the personnel and
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8. While screening tools can narrow the number of high-risk sites, only wall-thickness mapping at each site will give you an accurate picture of FAC damage. The mapping process requires removal of thermal insulation, painting of a closely spaced grid, and numerous measurements of actual wall thicknesses using manual ultrasonic testing