hrsg service solutions

HRSG SERVICE SOLUTIONS

Services for thermal power plants

Alstom is dedicated to keeping thermal power plants

competitive. Thanks to our OEM (Original Equipment

Manufacturer) expertise and involvement in around 25% of

the world’s power production capacity, we operate from a

position of proven expertise. With 15,000 power industry

professionals spread across 200 world-wide locations, Alstom

Thermal Services supports customers by providing extensive

service solutions; for daily operations and maintenance and

for lifecycle management challenges.

In a changing competitive and regulatory environment,

flexibility and expertise are key. Building on our global fleet

and project execution experience, we partner with owners

of Alstom and other OEM equipment to help maximise

performance and lifetime profitability while keeping safety,

reliability and environmental compatibility top priorities.

Alstom is a global organisation that cultivates cutting-edge

expertise at the product/technology level while maintaining

a strong local presence to meet site-specific needs and to

efficiently deliver tailored solutions in both established and

emerging markets. Whether you require support in the areas

of skills or systems, we have the technology, solutions and

presence to meet all your needs.

In today’s dynamic markets, the traditional concept of baseload production is increasingly challenged by the influx of intermittent sources. Price competition and stringent emissions regulations make the need for flexible operations greater than ever.

In Combined Cycle Plants or industrial cogeneration plants, the Heat Recovery Steam Generator (HRSG) makes a vital contribution to total plant efficiency. But as a large metal structure exposed to wide temperature fluctuations, the HRSG needs proactive attention to ensure continued reliability as operational modes become more dynamic.

Experience driven proactivity As a leading Original Equipment Manufacturer (OEM) and provider of turnkey combined cycle power plants, Alstom has unrivalled expertise relating to the design and optimisation of HRSG systems.

• Our boiler-making experience now stretches back over 100 years and includes the heritage of major boiler manufactur-ers, such as Combustion Engineering (CE) in the USA as well as EVT, Stein Industries and NEI in Europe.

• Thanks to our global field service network and an installed base of more than 600 HRSGs, we know how to operate and maintain heat recovery and steam generation systems to maximise the whole plant availability and reliability through-out the plant lifecycle.

Local, global, universalBy partnering with Alstom for your HRSG operations and maintenance, you get the best mix of local capabilities, regional hubs and global expertise. Irrespective of the OEM brand of your equipment, you can benefit from our unique portfolio of assessment technologies. And of course, we don’t just identify the problem, we provide viable tailored solutions that match your needs and maximise your plant potential.

Forward thinking services

Dynamic markets pose new flexibility and reliability challenges for the HRSG

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How Alstom is helping you meet the challenges of energy sustainability Clean Power, Clear Solutions

Our Power generation offering is based on a deep understanding of power markets and our customers’ needs. It is organised around three levers to maximise the return of assets over their entire lifecycle.

REDUCING COST OF ELECTRICITY

It takes competitive assets to keep electricity affordable. We enable power companies to compete successfully in the marketplace and provide affordable electricity to consumers. We help you reduce the cost of electricity through:

• Efficiency improvements• CAPEX reduction / scaling up• Capacity Factor increase (renewable)• Lead time reduction• Competitive O&M• Competitive financing

LOWERINGENVIRONMENTAL FOOTPRINT

Clean generation is one way of demonstrating environmental responsibility. Another is lowering resource usage, visual impact and noise pollution. In both cases, we can help you meet or exceed regulations and environmental standards. That is why Alstom innovates in the following areas:

• Renewable portfolio• Natural resource optimisation• Pollutants control

(SOx, NOx, PM, mercury)• CO2 emission reduction & CCS• Land use, visual impact and noise• Water intensity reduction &

recyclability

INCREASINGFLEXIBILITY & RELIABILITY

Intermittent power generation is a growing challenge of energy security, as is maintaining an aging installed base and adapting it to changing market conditions. We help you tackle both issues so that you can enjoy dependable operations with:

• Maintainability and outage time reduction

• Operational and fuel flexibility • Designs and service for improved

availability and reliability• Climate packages• Energy storage

How Alstom is helping you meet the challenges of energy sustainability Clean Power, Clear Solutions

REDUCING COST OF ELECTRICITY

Maintained HRSG performance in between inspections by installation of an on-line acoustic cleaning system

LOWERINGENVIRONMENTAL FOOTPRINT

>80% Reduction of CO emission by retrofit of CO catalyst


<30%* plant load. Minimum turn down rate reductions with emission compliancy (*depends on local limits)

PresenceWith operations in more than 70 countries, Alstom Power is close to customers all over the world. Thanks to our teams of trained and certified HRSG field specialists, you are assured of service excellence and rapid responses at all times. Building on our historical HRSG competence centres and OEM construction capabilities we now have a powerful and cost-effective global presence.

• 62 local service centres serving 70 countries• 12 locations with HRSG field service resources• 2 global HRSG service engineering centres

Global HRSG Service engineering centres

Local HRSG Field Services

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Our capability pillars Matching your priorities

Technology Thanks to our OEM expertise and service-focused R&D, Alstom has a number of technology-driven solutions for HRSG operations, maintenance, outage management and lifecycle optimisation. Our key technologies focus on:

• Life assessment - from code calculation to detailed finite element analysis• Performance modelling• Numerical or physical flow modelling• Structural design - pipework or structures• Metallurgical analysis• Water and steam cycle chemistry

Solutions The HRSG system makes a vital contribution to the overall per-formance of a power plant. That is why Alstom offers a one-stop shop with a full portfolio of solutions for this valuable but often underestimated asset. From optimising operations and mainte-nance to lifetime extension or upgrades for power and flexibility, we have the expertise and the implementation capabilities that only a global OEM and field service provider can deliver.

Alstom solutions cover the whole HRSG lifecycle and include:

• Technical expertise and operational support• Field service, parts and repairs• Life extension and performance improvement

>100 years boiler-building experience

>700 HRSG’s supplied

>50 HRSG inspections per year

>50 trained HRSG inspectors

>260 project & design engineers

>62 local service centres

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Our capability pillars Matching your priorities

Parts Supplying parts for HRSG units requires large scale facilities and extensive EPC experience. As an OEM with a global workshop network, Alstom can offer standard and tailor-made parts for all types of heat recovery equipment. No matter how large the part or how complex the installation, Alstom has a solution to streamline your maintenance and improve your unit availability.

Pressure parts and assemblies

• Harp assemblies• Tubing• Dissimilar metal weld inserts• Spacers, attachments, hardware• Drum internals, liners, nozzles

Fabricated parts and boiler mountings

• Access doors • Ducts, dampers• Baffles, expansion joints• Liner systems• Casing, structural steel, platforming• Drain lines, vents and drains

Control products

• Safety valves• Silencers• Desuperheaters• Instrumentation

Alstom offers a one stop solution for all your HRSG service needs.

Besides parts, Alstom also offer on-site testing and recommissioning as well as construction and installation services.

Deeper insights, better designs

Our deep understanding of HRSG degradation processes allows us to proactively address issues with timely interventions or improved designs for replacement parts.

Typical causes of parts degradation:

• Creep and low cycle fatigue• Quench effects: condensate flooding or desuperheater overspray• Corrosion: flow accelerated corrosion, under deposit corrosion, pitting during

shutdown, corrosion fatigue, standstill and acid dew point corrosion (gas side)• Overheating: gas by-passing, supplementary firing effects• Deposits / fouling (e.g. from SCR, corrosion)

30-40% time saving on a pressure parts replacement project due to Alstom‘s patented condition assessment tools.

INCREASING FLEXIBILITY & RELIABILITY

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Comprehensive solutions Securing lifetime productivity

Alstom offers a complete portfolio of products and services for the Heat Recovery Steam Generator (HRSG),

regardless of OEM manufacturer, type or application. Building on extensive experience we understand and

solve the challenges faced by combined cycle plant operators throughout the world with:

• Parts

• Repairs

• Field service

• Technical expertise and operational support

• Performance improvements

• Service contracts

• Services on other original equipment

manufacturers’ products

Repairs and field servicesLeveraging the presence and competence of our global field service and workshop networks, Alstom offers time-saving and added value repairs and field services for your HRSG and auxiliary systems. To optimise plant availability, we make minimising outage dura-tion a top priority: this begins with accurate information and effective planning. And by offering a one-stop solution, we provide our customers a more efficient outage.

Inspection services To help ensure an effective outage, we offer our inspection service that includes:

• Pre-outage unit walk-downs• Detailed inspections during the outage• Determining equipment condition and

need for repairs• Initial report with critical findings and

recommendations• Coordination with repair personnel

Condition assessmentAlstom repairs and field services are faster and more efficient thanks to cutting-edge technologies including:

• Phased array ultrasonic examination• Radiography• Surface replication• Metallurgical tube sample analysis• Boat and core sample analysis • Alloy identification• Thickness measurement• Magnetic particle testing• Boroscope internal video

Outage supportWith extensive experience we help customers increase availability and save costs before, during and after outages.

Planning• Setting objectives, work scope

and priorities• Material and parts requirements

and logistics

Execution• Best practices for disassembly

and assembly • Quality control • On-site modifications• Expert supervision

Looking forward• Final reports of work performed

and recommendations for next inspections or interventions.

Comprehensive solutions

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Securing lifetime productivity

Technical expertise and operational supportWith Alstom support, you can quickly find the right solutions to optimise all aspects of plant performance. We offer best-in-class technical assistance and support for any manufacturer’s design through our teams of support service engineers who build on the experience of an unmatched installed base.

Our solutions include:

• Operational flexibility reviews• Remaining life assessment• Reliability roadmapping - CA-PROSM service• Material testing and laboratory services• Chemistry reviews• Root cause analysis• Condition monitoring and diagnostic support• GT upgrade studies• Arrangement planning and structural design

Service contracts - Dedicated engineers

An experienced Alstom Services Engineer can be dedicated to work as a member of your plant team on-site for an exclusive period of time. This arrangement ensures the fastest possible identification of root cause problems and the timely develop-ment and implementation of solutions that reach or exceed your goals.

Training

Alstom offers standard or customer-specific training on HRSG operations and maintenance to help customers build in-house competence.

• Regular HRSG training seminars• Hands-on or simulator based operator training at Alstom’s or

customer’s facilities• Welding techniques and non-destructive examination (NDE)

61% Start-up time reduced from 90 to 35 minutes by design and installation of a reheater warm-up line.


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Comprehensive solutions For operational confidence

With the market for thermal energy becoming increasingly dynamic, plant owners are looking for reliable expert advice to optimise their operations and maintenance in fluc-tuating markets.

GT upgrade study

GT performance upgrades enable plant owners to keep up to date with shaftline technology developments. But upgrading the GT inevitably leads to changes in flue gas temperature and mass flow at the HRSG inlet. To avoid negative impact on the lifetime, reliability or performance of the HRSG, we recommend an GT upgrade study.

Using Alstom’s proprietary software to model any type of HRSG design we can predict the effect of the GT upgrade on the perfor-mance and life of your HRSG. Based on the output of the model we further investigate the areas of:

• HRSG performance• Pressure part material• Piping design• Emissions control• Flow Accelerated Corrosion (FAC)• Attemperation system • Valves and instrumentation

Optional assessments include on-line temperature profile meas-urements or Computational Fluid Dynamics (CFD) modelling to quantify the effect the GT exhaust gas profile has on flow distribu-tion and HRSG performance.

Flexibility reviewIn many markets, the HRSG must now be capable of frequent starts, rapid load transients and prolonged periods of low load operation.

During an operational flexibility assessment, Alstom uses analyti-cal techniques to assess transient behaviour and stress. Lifetime consumption will be balanced against business opportunities and critical areas will be identified. We then help you develop a plan to optimise plant reliability and performance during flexible operation.

Remaining life assessmentAlstom HRSG lifetime assessments identify critical components and operating practices to help prevent costly failures. Choose the service level you need:

• Inspection• Condition assessment• Remaining lifetime calculations• Detailed finite element analysis


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For operational confidence

Performance improvements To stay competitive, plant owners need to regularly improve HRSG performance. Leveraging OEM and service know-how Alstom offers cutting-edge solutions for improvement on all makes of HRSG.

• Operational flexibility improvements• Lifetime extension• Retrofit SCR/CO control system • Adaptations for GT upgrades• Baffle repair and improvement• FAC resistance• Accessibility improvements• Component and material upgrades• Piping system upgrades• Condition monitoring systems• Special applications and unique design challenges

Performance testing and evaluations

To provide a solid factual basis for performance improvements Alstom offers a range of advanced performance testing methods and solutions:

• HRSG and power plant performance evaluation• Water chemistry consultation for HRSGs• Instrumentation, supply and rental of most commonly

used HRSG and emissions test equipment

Operational flexibility improvements

Based on the HRSG flexibility assessment we can address the challenges of frequent cycling or a greater load range with:

• Improved draining systems• Piping flexibility modifications• Redesign of pressure parts• Lifetime monitoring equipment• Valve arrangements for improved control• Automation• Retrofit of CO catalyst for improved turn down• Desuperheater upgrades• Proactive inspection scopes

Pressure part replacement and upgrades

To increase flexibility and reliability, Alstom offers performance enhancing modifications to piping and pressure parts.

• Material upgrades for corrosion sensitive areas• Enhancement of header or harp assemblies for improved flex-

ibility or access• Modification or rerouting of piping systems for improved

access, improved drainage, elimination of water hammer etc.• Modification of pipe support system to reduce pipe loading

and improve flexibility


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Performance improvements focused on your priorities

Installation of condition monitoring

The addition of an online condition monitoring system is a big step towards greater reliability and availability for the whole plant. We recommend:

• Fatigue monitoring for components subject to rapid thermal transients and/or with significant wall thickness.

• Creep monitoring for components operating at high temperature.

• Temperature difference monitoring for components susceptible to conden-sate buildup, desuperheater leakage, overspray, etc.


HP drum- Fatigue

Superheater and reheater outlet harp headers- Creep

Reheater inlet manifold- FatigueLower manifolds

- Top-to-bottom temperature difference (condensate detection)

Superheater outlet manifold- Fatigue and creep

Desuperheaters- Top-to-bottom

temperature difference (overspray and flooding detection)

Reheater outlet manifold- Fatigue

and creep

Performance improvements focused on your priorities

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Technology through service-focussed R&D

To ensure that our HRSG solutions are informed and supported by the latest cutting-edge technologies, Alstom maintains in-house R&D facilities with capabilities that include:

• Finite element analysis• Flow accelerated corrosion (FAC) troubleshooting including

water chemistry analysis• Flow analysis using computer and physical modelling

techniques• Creep and fatigue life analysis and prediction• Assessment of effects of oxidation, corrosion and chemical

attack on pressure parts• Structural design

Alstom’s materials lab in Chattanooga is able to provide full metallurgical examination and analysis to determine the cause of failures or to determine the condition of components. Further capabilities include:

• Water and steam cycle chemistry • Analysis of deposits or corrosion products

Butt weld inspection scanner

Alstom Inspection Robotics has developed the Handheld Encoded Scanner (HES 100) for non-destructive flaw detec-tion. Thanks to phased array ultrasonic technology with encoder position feedback, butt weld inspections are now more precise and reproducible than ever. Unlike radiographic approaches, inspection is possible without evacuation of the inspection area. The unique flat design of the probe and the scanner allows the device to access tubes in very confined spaces with little clear-ance. The special shape and kinematics of the scanner enable the operator to work easily and effectively.

The HES 100 reveals the presence, circumferential size and radial position of flaws.

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Integrating plant, process and customer knowledge Deeper technology

Integrating plant, process and customer knowledge Deeper technology

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Modification for 2 shift operation - flexibility

An ageing plant designed for baseload operations needed to be modified to allow two shift operation.

SolutionAlstom began with a mechanical integrity assessment of exist-ing components. Then a tailored upgrade package was proposed and implemented. This included modifications to the start/stop sequence automation, improving the drum level control with a start-up control valve, modifying the superheater drain system to avoid condensate build-up and additional start-up vents to allow independent starting. Finally the economiser headers of the HP and IP were split.

Results After these modifications, the HRSG was able to operate reliably in a daily start/stop mode.

Specifications

• Customer location: UK• HRSG manufacturer: non-Alstom

Header replacement - reliability

The customer was suffering tube leaks due to flow accelerated corrosion (FAC). This is the loss of protective magnetite and base metal caused by water or wet steam flows. Performance loss caused by plugged tubes was becoming an issue for this customer.

SolutionAlstom’s solution optimised the outage process, HRSG design and chemistry. A staggered header design allowed in-situ welding and the Alstom HES100 ultrasonic scanner (pictured above) was employed to ensure the quality of each welded joint.

ResultsReplacing the LP evaporator headers while employing 2.25% Cr steel increased FAC resistance and the overall unit reli-ability. The outage was completed in 30 days instead of the 50 days that are typically required for this kind of outage. This was achieved by using ultrasonic testing instead of radiography.

Specifications

• Customer location: UK• HRSG manufacturer: non-Alstom

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Increasing flexibility, reliability and safetySuccess stories

Demister design and application for EHS

Excessive moisture in the plant plume was causing hazard-ous mist on a nearby highway during the cold winter months. Alstom was asked to tackle the problem.

SolutionIn a two phase project, Alstom reviewed the options and submitted recommendations. Then the selected design was developed and implemented. Alstom supplied three moisture elimination vessels along with associated steel and piping.

ResultsThe hazardous situation on the highway was eliminated.

Specifications

• Customer location: US• HRSG manufacturer: Alstom

Adaptation for GT upgrade & flexibility

To support daily cycling and adapt to a GT upgrade, Europe’s oldest energy production company asked Alstom to propose a package of HRSG measures.

SolutionAlstom verified the design of the HRSG with respect to the new GT flue gas conditions. To cope with the daily starts and stops, a new drain system was added along with a vent for addi-tional flexibility. The drum level control valve was replaced and cyclical life analysis permitted the start up time to be reduced. An attemperator was added to allow GT loading without hold points from the steam turbine.

ResultsThese modifications gave the plant the full value of the GT upgrade. The HRSG was able to switch from base load opera-tions to operating in a daily start/stop mode.

Specifications

• Customer location: Italy• Plant: 140 MW, GE GT100• HRSG: Cei/Vogt

Increasing flexibility, reliability and safetySuccess stories

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Rail transport

Electrical grid

Power generation

Alstom is a global leader in the world of power generation, power transmission and rail infrastructure and sets the benchmark for innovative and environmentally friendly technologies.

Alstom builds the fastest train and the highest capacity automated metro in the world. It also provides turnkey integrated power plant solutions and associated services for a wide variety of energy sources, including hydro, nuclear, gas, coal, wind, solar thermal, geothermal and ocean energies. Alstom offers a wide range of solutions for power transmission, with a focus on smart grids.

Alstom

Alstom Power offers solutions which allow our customers to generate reliable, competitive and eco-friendly power.

Alstom has the industry’s most comprehensive portfolio of thermal technologies – coal, gas, oil and nuclear. With leading positions in turnkey power plants, power generation services and air quality control systems, Alstom is pioneering developments in carbon capture technologies.

Alstom offers the most comprehensive range of renewable power generation solutions. Today we offer hydro power, wind power, geothermal, biomass and solar. And with ocean energies, we are developing solutions for tomorrow.

Alstom is one of the world leaders in hydro power, the largest source of renewable energy on the planet.

Power generation

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.com ALSTOM Power Inc. (US)200 Great Pond DriveWindsor, CT 06095-0500 United States Telephone: +1 866 257 8664 ALSTOM Power Service (UK)Power House, Silverlink Business Park, Wallsend, Tyne & Wear NE28 9ND United Kingdom Telephone: +44 (0)191 295 2100

Alstom PowerBrown Boveri Str. 75401 BadenSwitzerland

www.alstom.com

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