Diagnostic - Troubleshooting HRSG

Diagnostic/Troubleshooting Monitoring to
Identify Damaging Cycle Chemistry or

Thermal Transients in Heat Recovery Steam
Generator Pressure Parts
SED
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Technical Report
Diagnostic/Troubleshooting
Monitoring to Identify Damaging
Cycle Chemistry or Thermal
Transients in Heat Recovery Steam
Generator Pressure Parts
1008088
Final Report, March 2005
EPRI Project Manager

R. B. Dooley
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
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J. Michael Pearson & Associates Co. Ltd.
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CITATIONS
This report was prepared by
EPRI
3412 Hillview Avenue
Palo Alto, CA 94304
Principal Investigator
R. B. Dooley
Aptech Engineering Services, Inc.
1253 Reamwood Avenue
Sunnyvale, CA 94089
S. Paterson
J. Michael Pearson & Associates Co. Ltd.
9 Abbit Crescent, RR1
Georgetown, Ontario
Canada L7G4S4
M. Pearson
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Diagnostic/Troubleshooting Monitoring to Identify Damaging Cycle Chemistry or Thermal
Transients in Heat Recovery Steam Generator Pressure Parts, EPRI, Palo Alto, CA: 2005.
1008088.
iii
PRODUCT DESCRIPTION
The worldwide fleet of combined cycle units with heat recovery steam generators (HRSG) has
exhibited a disappointing track record with respect to reliability and availability in terms of
HRSG Tube Failures (HTF). This report will assist operators in identifying the harmful chemical
and thermal transient excursions that lead to failure.
Results & Findings
The report provides a series of road maps to identify, measure, evaluate, correct, and control
those cycle chemistry and thermal transients that result in poor HRSG reliability within the
design life of a generator. Particular emphasis has been given to eliminating failures in the first
few years of operation. The appendices of the report include background information on tube
temperature measurement, cycle chemistry monitoring, and estimates of cost.
Challenges & Objectives
The most frequently occurring HTF damage mechanisms include thermal and corrosion fatigue,
thermal quench cracking, flow-accelerated corrosion, and under deposit corrosion. These are
either influenced by transiently high, thermally induced cyclic stresses or inadequate feedwater
and evaporator chemistries. On the chemistry side, it is clear that the chemistries adopted during
the design phase of a plant set the stage for later failures. The objective of this work was to
develop a comprehensive approach that will identify and eliminate non-optimum cycle
chemistries and avoid potentially damaging thermal transients in the various HRSG circuits as
early in life as possible.
Applications, Values & Use
Organizations that apply the monitoring and diagnostic approaches delineated in this report can
operate HRSGs with added confidence that chemical and thermal effects have been identified
and will not lead to HTF damage and failure. Adoption of the necessary practices will put an
organizations HRSG on the road to world-class performance.
EPRI Perspective
To address the suite of issues related to HTF, EPRI has developed a series of documents: HRSG
Cycle Chemistry Guidelines (EPRI report TR-110051), HRSG Tube Failure Manual (EPRI
report 1004503), and Delivering High Reliability HRSGs (EPRI report 1004240). However,
these documents by themselves would not lead to a reduction in repeat HTF because many of the
influencing features leading to failure were an integral part of the original specification and
design aspects or resulted from inadequate commissioning. Organizations needed an approach to
recognize these deficiencies in the early life of an HRSG. The current document provides this
methodology. The next steps are to conduct a number of case studies to illustrate the efficacy of
the approach.
Approach
The EPRI team first developed an interim White Paper on the topic. This document was used to
solicit host HRSGs. The team worked with one host site, reviewed its chemistry and possible
thermal transients, and made suggestions for installation of thermocouples and for cycle
chemistry monitoring. Based on this exercise, the team upgraded the white paper to the current
report.
Keywords
Heat recovery steam generator (HRSG)
Combined cycle units
Tube failures
Thermal transients
Cycle chemistry
Monitoring and diagnostics
vi
EPRI Licensed Material
ABSTRACT
To identify the root causes of the leading HRSG Tube Failure (HTF) mechanisms, and to
identify damage accumulating from non-optimum cycle chemistry and severe thermal transients,
it is necessary to conduct diagnostic monitoring. This report, which is within a series of EPRI
reports, provides details and case studies of how to conduct monitoring of HRSG tubing and
header/tubing attachments. A road map approach is provided with numerous examples.
vii
ACKNOWLEDGMENTS
The authors of this report
R. B. Dooley, EPRI
S. Paterson, Aptech Engineering Services, Inc.
M. Pearson, J. Michael Pearson & Associates Co. Ltd.
acknowledge the contributions from the following individuals:
Kevin Shields, EPRI
Kurt Koenig, Plant Engineer, Jasper Plant, SCE&G
Steve Palmer, Plant Manager, Jasper Plant, SCE&G
John Pearrow, Manager System Chemistry, Jasper Plant, SCE&G
Galen Bullock, Maintenance Superintendent, Jasper Plants, SCE&G
ix
CONTENTS
1 INTRODUCTION....................................................................................................... 1-1
1.1 Background....................................................................................................... 1-1
2 STEPS FOR THE IDENTIFICATION, CORRECTION AND CONTROL OF
CYCLE CHEMISTRY OR THERMAL TRANSIENT INFLUENCED HRSG
PRESSURE PART DAMAGE...................................................................................... 2-1
2.1 Introduction to Road Map Steps........................................................................ 2-1
2.2 Step 1: Review of Unit Design, Operational and Maintenance Information....... 2-2
2.2.1 Cycle Chemistry Review ............................................................................ 2-2
2.2.2 Review of Pre-operational and Layup Practices ...................................... 2-11
2.2.3 Review of Thermal-Mechanical Parameters ............................................ 2-12
2.3 Step 2: Identifying the Potential Cycle Chemistry or Thermal-Mechanically
Influenced Damage Mechanisms........................................................................... 2-15
2.4 Step 3: Specify the Type and Locations for the Diagnostic Instrumentation ... 2-16
2.5 Step 4: Install High Priority Diagnostic Instrumentation .................................. 2-29
2.6 Step 5: Operate Unit over a Wide Range of Operating Conditions ................. 2-30
2.7 Step 6: Review and Evaluate the Results of Diagnostic Instrumentation
Measurements ....................................................................................................... 2-31
2.8 Step 7: Evaluate, Engineer and Implement Operational, Maintenance and
Design Enhancements to Ameliorate or Eliminate Damage Influencing Cycle
Chemistry or Thermal-Mechanical Events ............................................................. 2-33
2.9 Step 8: Verify the Success of the Changes through Additional Monitoring
and Evaluation ....................................................................................................... 2-34
2.10 Step 9: Ongoing Monitoring, Evaluation, and Improvements ........................ 2-34
3 REFERENCES.......................................................................................................... 3-1
A BACKGROUND INFORMATION REVIEW ............................................................. A-1
General Plant/Unit Information.................................................................................A-1
xi
Cycle Chemistry Information ....................................................................................A-2

Thermal Cycling Information ....................................................................................A-2
B IDENTIFYING POTENTIAL DAMAGE MECHANISMS AND DIAGNOSTIC
MONITORING NEEDS................................................................................................ B-1
Personnel Involved ..................................................................................................B-2
Objectives ................................................................................................................B-2
C MONITORING GAS, FLUID, AND TUBE METAL TEMPERATURES.................... C-1
Thermocouple Installation Process Specification.................................................... C-2
Process Specification.............................................................................................. C-2
Additional Important Installation Requirements....................................................... C-3
Data Recording ....................................................................................................... C-3
Photos of Installation Steps..................................................................................... C-4
Capacitance Discharge Weld Qualification ........................................................... C-11
D COST FOR A 96 THERMOCOUPLE MONITORING SYSTEM .............................. D-1
xii
LIST OF FIGURES
Figure 1-1 Cycle chemistry evaluation, and improvement road map: feedwater (all1
ferrous cycles) ...................................................................................................................1-5
1
Figure 1-2 Cycle chemistry evaluation, and improvement road map: evaporator water ...........1-6
Figure 1-3 Thermal transient evaluation and optimization road map .........................................1-7
Figure 2-1 Example generic cycle chemistry diagram for a triple pressure HRSG with
reheat .................................................................................................................................2-4
Figure 2-2 Cycle chemistry diagram showing the chemical feed and chemistry
monitoring locations in a triple pressure HRSG with reheat that is controlled with
ammonia additions in the feedwater and trisodium phosphate additions to the IP
and HP drums. ...................................................................................................................2-5
Figure 2-3 Total (particulate + soluble) iron levels measured in each of three HRSGs
after a few months of plant operation. Note that the iron concentrations are close to
the desired value of less than 5 ppb for all the sections of the cycle except the
intermediate pressure drums. ..........................................................................................2-11
Figure 2-4 Characterization of an aggressive basic thermal shutdown and startup cycle. ......2-15
Figure 2-5 Example of a preliminary 21 day in-situ test to confirm that reducing the
injection of hydrazine does reduce the total level of iron in the feedwater.
Subsequently on this unit, the reducing agent was eliminated.........................................2-17
Figure 2-6 Example arrangement of a set of thirteen diagnostic/ troubleshooting
thermocouples that identified and quantified the magnitude of cold startup related
row-to-row and element-toelement tube temperature differences in an HRSG
reheater bundle. Prior to introducing steam flow (at approximately 38 minutes after
combustion turbine startup) the leading row tubes (Row A) were approximately
o
o
55 C (100 F) hotter than the trailing, Row B tubes. After introducing steam flow, two
of the leading row tubes near the right hand side of the bundle were rapidly
quenched to near the estimated saturation temperature. This forward flow of
saturated liquid (most likely undrained condensate) resulted in a tube to tube
o
o
temperature difference near 140 C (250 F). In more recent tests on another design
o
o
of HRSG tube-to-tube temperature differences in excess of 167 C (300 F) were
recorded. ..........................................................................................................................2-24
Figure 2-7 Example of the location of twenty eight diagnostic/ troubleshooting
thermocouples installed in a vertical tube high pressure economizer tube bundle. .........2-26
Figure 2-8 Seven high pressure economizer tube Row A (just beneath the outlet
header, see Figure 2-7) thermocouples measurements during a cold start. At this
location the measurements suggest that the HP economizer approach temperature
o
o
is at least 10 F (6 C) and the tube to tube temperature differences are less than
o
o
25 F (14 C). No steaming or severe tube to tube temperature differences would be
indicated from these thermocouples. ...............................................................................2-27
xiii
Figure 2-9 Seven high pressure economizer tube Row B (just after the final upper
return bend, see Figure 2-7) thermocouples measurements during a cold start. At
this location the measurements indicate that the water in four of the seven tubes is
o
o
more than 25 F (14 C) above the estimated saturation temperature (i.e., air-locking
or steaming is occurring in the tubes near the edges of the bundle). This resulted in
o
o
a tube to tube temperature difference near 80 F (44 C)...................................................2-27
Figure 2-10 Seven high pressure economizer tube Row C (just after the first upper
return bend, see Figure 2-7) thermocouples measurements during a cold start. At
this location the measurements indicate that the water in one of the seven tubes is
o
o
more than 10 F (6 C) above the estimated saturation temperature (i.e., air-locking
or steaming is occurring in at C23). Since the water in the other tubes is more than
o
o
100 F (55 C) below the saturation temperature this results in a tube to tube
o
o
temperature difference that is greater than 100 F (55 C). ................................................2-28
Figure 2-11 Seven high pressure economizer tube Row D (in the vertical downflow
tube just beneath the inlet header, see Figure 2-7) thermocouples measurements
during a cold start. At this location the measurements indicate that the water in the
three cooler tubes, which are probably representative of the majority of tubes in the
row, remains close to the HP economizer feedwater inlet temperature, whereas the
fluid in the other tubes with TCs (that are close to the blind ends of the inlet header
o
o
and further from the inlet pipes on the header) operate up to 67 C (120 F) hotter
than the coldest tubes due to either flow stagnation or reverse, recirculating flow
upwards in the tubes with the lowest pressure drop between the upper inlet and
lower return header. Lower flow and high temperatures in the tubes furthest from
the inlet pipes were caused by higher hydraulic resistance and buoyancy forces in
the water in these tubes. Gas laning and elevated heat absorption in the tube
circuits near the sides of the bundle may have been partially responsible for the
increased buoyancy forces, reduced flow and elevated water temperature
observed. .........................................................................................................................2-29
Figure 2-12 Time line plot of the bulk temperatures measured up and downstream of a
single parallel pass, two row, vertical tube, finishing (high temperature) reheater
4
during a warm start made with a low hot reheat steam temperature setpoint . Two
significant temperature drops were observed. The first occurred soon after steam
flow was established through the reheater bundles and was attributed to forward
flow of undrained condensate. The second event was more severe and was caused
by overspraying of the interstage attemperator too close to saturation temperature.
Operating practices that contributed to the overspraying were substantial lowering
of the RH steam outlet temperature setpoint and excessively aggressive ramping of
the CT load and exhaust gas temperature to the maximum gas temperature.
Simultaneous raising of HP pressure exacerbated the severity of the event. ..................2-32
Figure 2-13 Spatial temperature plot of 74 reheater tube thermocouples. This time slice
was associated with the attemperator overspray event shown in Figure 2-12. Some
o
o
tubes were more than 83 C (150 F) hotter than the adjacent tubes. The tubes near
the inlet nozzle centered above tube element #9 were severely cooled in both tube
rows. Near the other inlet nozzles the dogleg tube row (Row #2) was being cooled
well below the straight, leading row of tubing...................................................................2-33
Figure B-1 Location of thirty two thermcouples to be installed in direct contact with the
tube OD surface between the finned tubing and the headers ........................................... B-8
Figure B-2 Location of fourteen thermocouples to be installed in direct contact with the
tube OD surface between the finned tubing and the headers ........................................... B-9
xiv
Figure B-3 Location of eighteen thermocouples to be installed in direct contact with the
tube OD surface between the finned tubing and the headers ......................................... B-10
Figure B-4 Location of three thermocouples to be installed in direct contact with the OD
surface of the downcomer on the east tube bundle ........................................................ B-11
Figure B-5 Location of fifteen thermocouples to be installed in Bundle A in direct contact
with the tube OD surface between the finned tubing at three locations on 5 tube
elements.......................................................................................................................... B-12
Figure C-1 Removal of a window of lagging and insulation on an HP downcomer.................. C-4
Figure C-2 Removal of surface oxide with gentle grinding ...................................................... C-5
Figure C-3 Preheating of cleaned surface and verification of the surface temperature
with a Tempil stick............................................................................................................. C-6
Figure C-4 Attachment of the work lead (attached with a magnet) and the electrode lead
(thermocouple wire held on the surface with a plier which is electrically connected
to the capacitance discharge power supply. ..................................................................... C-7
Figure C-5 Completed thermocouple junction welds ............................................................... C-8
Figure C-6 Supporting and guiding the thermocouple wire from the thermocouple
junction to the data acquisition system. It is important that the wire is guided in a
manner that provides for thermal expansion and protection from personnel. ................... C-9
Figure C-7 Insulation covering the thermocouple junctions on a HPSH tube. The
insulation used was spare manway door insulation that was held in place with two
wraps of stainless steel wire. .......................................................................................... C-10
Figure C-8 Mock-up T91 tube that was used to qualify the thermocouple junction
welding procedure. Note the two unsuccessful welds above the completed welds.
Unsuccessful weld junctions should be removed by light grinding.................................. C-11
Figure C-9 Polished metallurgical cross-section of one of the mock-up thermocouple
junctions. Although this junction has some minor porosity, undercut and incomplete
fusion it will provide accurate temperature readings and will probably have
adequate reliability. ......................................................................................................... C-11
Figure C-10 Cross-section through another thermocouple junction. This junction has
severe porosity and small cracks (see Figure C-11). This thermocouple junction will
provide accurate temperature readings but is not adequate if longevity and
resistance to in-service cracking are important. .............................................................. C-12
Figure C-11 Close-up of the thermocouple junction shown in Figure C-10. Note the
severe porosity, and cracks that extend toward the tube surface. The tube surface
beneath the weld will have a shallow, but very hard heat affected zone. The
combination of porosity, microcracks, and the hard base metal heat affected zone
could lead to cracking. .................................................................................................... C-12
xv
LIST OF TABLES
Table 2-1 Example of Measured or Recommended Cycle Chemistry Parameters for a
Triple Pressure HRSG with Reheat Treated with Ammonia in the Feedwater and
Trisodium Phosphate in the IP and HP Drums. Selected measured values
measured at full load are shown in the right-hand column. (The values within this
table are not all in line with the EPRI Guideline values and should not be applied to
1
the readers unit. Please see the EPRI Guidelines ) ...........................................................2-6
Table 2-2 HRSG Cycle Chemistry Monitoring Parameters ......................................................2-18
Table 2-3 HRSG Thermal-Hydraulic Monitoring Parameters...................................................2-21
Table A-1 DCS Attribute Grouping Useful for Identifying and Characterizing ThermalMechanical Cycles ............................................................................................................ A-3
Table B-1 Location and Number of Diagnostic Thermocouples .............................................. B-7
xvii
1
INTRODUCTION
1.1 Background
There have been numerous heat recovery steam generator (HRSG) pressure part failures that
have resulted from less than optimal cycle chemistry and damaging thermal transients. It is
estimated that poor cycle chemistry and damaging thermal transients are responsible for more
than 80% of the pressure part failures that have been experienced in HRSGs.
To address this concern EPRI developed the Interim HRSG Cycle Chemistry Guidelines1. These
guidelines provided road map approaches to the monitoring, optimization, and control of cycle
chemistry in single-, double- and triple-pressure combined cycle HRSGs. Next EPRI prepared
the HRSG Tube Failure (HTF) Manual2. This manual identified all the current HTF and ways of
preventing repeat failures. EPRI then recognized that there was a need for a more proactive
approach to prevention of HRSG pressure part damage. A report entitled Delivering High
Reliability Heat Recovery Steam Generators3 was prepared. This document presented needed
actions during the design, commissioning, and operation phases, etc. to prevent HRSG pressure
part damage and failures.
This latter effort, and recognition that pressure part failures caused by transiently high, thermally
induced cyclic stresses are becoming increasingly frequent, led to the need to compile
information on the world wide design codes dealing with fatigue and their deficiencies, and thus
the need to provide better guidance for the assessment of creep fatigue in components that
normally operate at higher temperatures, thermal fatigue in lower temperature components or
corrosion fatigue of HRSG pressure parts. It also led on the chemistry side to the clear
understanding that many of the chemistries adopted during the design phase are designed to fail.
Historically, poor commissioning practices have generally failed to identify or evaluate the
damaging consequences of either the thermal transients or the non-optimum chemistry. This
report provides a road map approach for identifying non-optimum chemistry regimes and
damaging thermal transients in the various circuits.
The most frequently occurring HRSG tube failure (HTF) damage mechanisms include:
1. Corrosion fatigue
2. Flow accelerated corrosion, single and two-phase
3. Underdeposit corrosion (hydrogen damage, acid phosphate corrosion, caustic gouging)
4. Pitting corrosion
5. Thermal quench-induced fracture
1-1

Introduction
6. Thermal fatigue
7. Creep fatigue
Damage mechanisms 2, 3 and 4 are predominately cycle chemistry influenced and mechanisms
5, 6 and 7 are thermal mechanical mechanisms. Damage mechanism 1 requires the simultaneous
occurrence of a corrosive environment and high thermally induced stresses.
Some common root cause factors for the cycle chemistry influenced failures include:
a) Initiating startup operation with a corrosive environment in the water, increasing the risk of
corrosion fatigue damage.
Deficient chemistry control.
Improper chemical cleaning.
Deficient startup operating practices.
Deficient design that incorporates features and details that develop high localized thermal
stresses in pressure parts.
b) Operation with a corrosive environment in flowing feedwater and/or steam-water mixtures,

increasing the risk of flow-accelerated corrosion.
Reducing feedwater chemistry (single-phase FAC) (i.e., oxidizing-reducing potential,

ORP, is in the negative range).
Entrained water droplets of low pH in steam-water mixture (two-phase FAC).
c) Operation with a corrosive environment beneath waterside deposits, increasing the risk of
underdeposit corrosion mechanisms including hydrogen damage (HD), acid phosphate
corrosion (APC) and caustic gouging (CG).
Excessive waterside deposits (all mechanisms).
Waterside flow disruptions (all mechanisms).
Improper gas side conditions (all mechanisms).
Improper selection/control of evaporator chemical treatments (all mechanisms).
Water treatment plant upsets (CG and HD).
Condenser leaks (HD).
Improper chemical cleaning (HD).
Nonoptimal phosphate treatment such as congruent phosphate treatment (APC).
d) Creation of a corrosive environment during idle periods.
1-2
Improper wet layup with stagnant oxygenated water.
Non use of nitrogen blanketing during shutdown.

Introduction
Improper chemical cleaning.
Carryover of sodium sulfate and deposition in reheaters (rare in HRSGs because of the
low number of units with condensate polishers).
Some common root cause factors for the thermally induced failures include:
a) In horizontal gas path HRSGs, transient tube-to-tube temperature variations in vertical tubes
connected to common upper and lower headers. These temperature differences are intended
to be very small. Typically well under 50oC (90oF). Tube-to-tube temperature differences
above 100oC (180oF) have been measured in numerous HRSGs. There are a variety of root
causes of these unanticipated and damaging temperature differences including:
Startup conditions with gas temperatures and flows that are excessive.
Forward flow of undrained condensate in HPSH or RHs during startups due to poor
design and/or arrangement of lower connecting pipes and the drains removal and disposal
systems or to incorrect operation.
Introduction of saturated or subcooled water into the HPSH or RH by over spraying

during startups and shutdowns or poor design and/or arrangement of the interstage
attemperators.
Delays in establishing natural circulation in successive rows of evaporator tubes during

cold startups.
Circulation of stratified, subcooled liquid in the HP evaporators during startups following

overnight or weekend shutdowns.
Introduction of cold feedwater into a hot stagnant LP economizer or preheater during

starts and drum top ups.
Introduction of hot recirculation water into the cool inlet of the LP preheater following
trips or shutdowns.
Steaming or air lock in some economizer tubes due to lack of or inadequate venting.
Periodic reverse or stagnant flow of feedwater in some economizer tubes during startups
or continuous flow recirculation on load.
Leakage of cooler feedwater into hotter sections of economizers through passing

maintenance drains.
b) Tube-to-header or through wall header temperature gradients must also be controlled to avoid
localized yielding and cyclic damage. Localized permanent cyclic damage may occur when
these gradients exceed a critical value that is dependent on the local geometry. These
damaging transients are caused by:
Excessively fast steam temperature and/or steam pressure increases during startups.
Headers are too thick and/or of large diameter.
Introduction of saturated or subcooled water such as undrained condensate or

attemperator spray water into the HPSH or RH.
1-3

Introduction
Introduction of cold feedwater into the economizer/evaporator headers/drum.
Periodic reverse or stagnant flow of feedwater in the economizer, during startups.
EPRI developed a benchmarking process where an organizations HRSG Dependability Program

ranks on a world class basis6. It is clear that although thermal- and cycle chemistry-induced
HRSG failures predominate, there has currently been very little effort by HRSG operators to
identify the precursors of failure on their units. EPRI has also developed a set of attributes that
are needed to put an organizations HRSG on the road to worldclass7. The need to identify the
thermal transients and deficiencies in cycle chemistry early in the life is one of the key features.
The objective of diagnostic/ troubleshooting monitoring is to identify and eliminate nonoptimum cycle chemistries and avoidable, potentially damaging thermal transients in the various
HRSG circuits as early in the life of unit as possible. This can be accomplished by applying a
road map approach (Figures 1-1 through 1-3) to the identification, measurement, evaluation,
correction, and control of those affects that may result in poor HRSG reliability within its
intended design life, with particular emphasis on eliminating failures in the first few years of
operation.
Section 2 of this report provides a nine step approach which can be followed to accomplish the
objectives stated above. Three appendixes provide: (i) a list of background information that
should be reviewed (Appendix A), (ii) examples illustrating the logical selection of locations for
tube temperature measuring thermocouples (Appendix B), (iii) a protocol for the installation of
tube temperature measuring thermocouples (Appendix C), and estimates of the costs to install
approximately 100 thermocouples in a tube temperature monitoring system (Appendix D).
1-4

Introduction
Figure 1-1
Cycle chemistry evaluation, and improvement road map: feedwater (all-ferrous cycles)1
1-5

Introduction
Figure 1-2
Cycle chemistry evaluation, and improvement road map: evaporator water1
1-6

Introduction
Figure 1-3
Thermal transient evaluation and optimization road map
1-7
2
STEPS FOR THE IDENTIFICATION, CORRECTION AND
CONTROL OF CYCLE CHEMISTRY OR THERMAL
TRANSIENT INFLUENCED HRSG PRESSURE PART
DAMAGE
2.1 Introduction to Road Map Steps

Time, cost, and difficult access to certain tube bundle locations places limits on the location,
type, and extent of diagnostic instrumentation that can be used to identify potential cycle
chemistry and thermal transient influenced HRSG pressure part damage. With the plethora of
HRSG designs it is also not possible to have a single approach that can be used for all units. On
the other hand, it is possible to provide a set of steps that can be followed to prescribe diagnostic
instrumentation requirements and use these measurements to make appropriate corrective
actions. The primary steps in this process include (Figure 1-3):
1. Review of unit design, operational and maintenance information.
2. Identify the potential cycle chemistry or thermal-mechanically influenced damage
mechanisms.
3. Specify the type and locations for the diagnostic instrumentation.
4. Install high priority diagnostic instrumentation.
5. Operate unit over a wide range of operating conditions.
6. Review and evaluate the results of diagnostic instrumentation measurements.
7. Evaluate, engineer and implement operational, maintenance and design enhancements to
ameliorate or eliminate damage influencing cycle chemistry or thermal-mechanical events.
8. Verify the success of the changes through additional monitoring and evaluation.
9. Ongoing monitoring, evaluation, and improvements.
This report is focused on the first four of these steps but includes some guidance on each step. A
companion report Evaluation of Creep-, Corrosion- and Thermal-Fatigue of HRSG Pressure
5
Parts addresses Step 6. Other projects are underway that will provide additional guidance and
case studies providing examples for every step in this process.
Each of the nine road map steps are described in more detail in the following sections.
2-1

Steps for the Identification, Correction and Control of Cycle Chemistry or Thermal Transient Influenced HRSG
Pressure Part Damage
2.2 Step 1: Review of Unit Design, Operational and Maintenance

Information
Working with the plant staff, the information listed in Appendix A should be collected and
reviewed. The objective of this review is to gain an understanding of the current design, and
operation and to identify major operational or design issues. It is important to emphasize during
this initial review that many of the more subtle, off-design problems that have caused HRSG
pressure part failures are sometimes impossible to identify with existing plant instrumentation.
2.2.1 Cycle Chemistry Review
The cycle chemistry review is usually relatively straightforward compared with the review of the
thermal hydraulic features. The primary effort required for the cycle chemistry review is the
preparation and review of a heat balance/cycle chemistry diagram for the unit. A custom cycle
chemistry diagram for each unit should be developed if these are not already available. The
generic cycle chemistry diagrams in EPRIs Interim Cycle Chemistry Guideline1 for HRSGs
(e.g., Figure 2-1) can be used as a guide but these should be customized to reflect the unique
circuitry, feed points and monitoring instrumentation of each unit (e.g., Figure 2-2).
The basis of these diagrams is the unit heat balance diagram. Superimposed on this diagram are
the continuous on-line instruments employed at each monitoring point around the unit. Then
typical values for each monitored parameter will provide good indications of how the unit is
running. Chemical injections into the feedwater and drum provide an instant indication of how
close the unit is to optimum treatments. Finally the grab sample analyses are added; most
important here are the total iron levels in the feedwater and each drum. After the cycle chemistry
diagram is prepared, a review to see if core cycle chemistry monitoring instrumentation is
present should also be made.
For example, from a comparison of the cycle chemistry diagram shown in Figure 2-2 with EPRI
1
Guidelines it clear that the following additional continuous monitoring instrumentation is
needed on this unit:
Demineralized makeup water effluent silica measured once per shift.
Cation conductivity of the feedwater downstream of the ammonia feed.
Cation conductivity of the LP drum saturated steam.
Cation conductivity and sodium of the LP superheat outlet steam.
Cation conductivity of the IP drum saturated steam.
Cation conductivity and sodium of the hot reheat steam.
Next the results of recent full load grab sample and on-line monitoring results should be
reviewed (e.g., Table 2-1 and Figure 2-3) to see what attributes are measured, what control or
action limits have been set and which parameters have been outside the optimum ranges. Using
this approach it is always possible to quickly identify non-optimal conditions that should be
corrected prior to any further operational transient studies. For example, although comprehensive
2-2

chemistry results were not available, the available measurements listed in Table 2-1 and Figure
2-3 identified the following issues:
The makeup and preheater inlet water have excessive conductivity and dissolved oxygen
contents.
The IP and HP evaporator water is showing phosphate and conductivity instabilities

suggesting moderate phosphate hideout and return may be occurring.
The IP evaporator water has high iron levels.
Based on these findings a more thorough investigation to determine the source of the high
conductivity and oxygen readings in the makeup and turbine condenser condensate water would
be performed, starting with independent measurements and instrument calibration or more
frequent and comprehensive grab sample analyses. Measurements of air inleakage would also be
made.
Ongoing IP drum water iron monitoring including some detailed monitoring performed during
thermal transients and following IP drum blowdown would be performed to attempt to
understand the reason for the elevated levels of iron in the IP evaporator.
The elevated conductivity and phosphate instabilities in the IP and HP evaporator water would
be investigated by checking the calibration of the instruments, and monitoring sodium,
phosphate, pH and cation conductivity and iron more frequently and over a range of operating
conditions. If further evidence of phosphate hideout was found then an internal videoprobe
examination of the leading row of HP and IP evaporator tubing would be performed. If waterside
deposits were observed then instrumentation to measure the gas temperature profile, circulation
ratios, and steam quality at various fired and unfired operating conditions in the HP and IP
evaporators would be performed. This detailed monitoring might include adding gas and midwall
chordal thermocouples into sections of the leading row tubing experiencing deposition. To
determine if the circulation and steam quality are acceptable may require installing flow meters
on each of the downcomers and a few selected riser tubes and pressure gages and thermocouples
on the top and bottom of the downcomers and deposition prone riser tubes.
2-3

Steps for the Identification, Correction and Control of Cycle Chemistry or Thermal Transient Influenced HRSG Pressure Part Damage
Figure 2-1
Example generic cycle chemistry diagram for a triple pressure HRSG with reheat
2-4

Figure 2-2
Cycle chemistry diagram showing the chemical feed and chemistry monitoring locations
in a triple-pressure HRSG with reheat that is controlled with ammonia additions in the
feedwater and trisodium phosphate additions to the IP and HP drums.
2-5

Table 2-1
Example of Measured or Recommended Cycle Chemistry Parameters for a Triple Pressure
HRSG with Reheat Treated with Ammonia in the Feedwater and Trisodium Phosphate in
the IP and HP Drums. Selected measured values measured at full load are shown in the
right-hand column. (The values within this table are not all in line with the EPRI Guideline
values and should not be applied to the readers unit. Please see the EPRI Guidelines1)
Location/
Parameter
Sample
Condenser Air Removal

Exhaust
Air inleakage Daily
SCFM/100
MW
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
>1
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
20
25
Immediate
shutdown
Measured
full load
values
Condenser Leak Detection Trays or Hotwell

Zones
Cation
Continuous
conductivity,
S/cm
*
*
Demineralized Makeup Water

Silica, ppb
Once per shift
Specific
Continuous
conductivity,
S/cm
pH
Hardness
Total organic Weekly or
carbon, ppb
Troubleshooting
Condensate Pump Discharge
Cation
Continuous
conductivity,
S/cm
Dissolved
Continuous
oxygen, ppb
(if not
measured at
economizer
inlet)
Sodium, ppb
Continuous
2-6
10
0.1
15
>0.2
0.50 to
1.02
7.1 to 8.1
0
300
>0
0.20
0.35
0.65
20
40
> 40
10
20
> 0.65
0.40 to
0.84
69 to 78
> 20

Location/
Parameter
Sample
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
Total organic
carbon, ppb
Iron, ppb
Weekly or
Troubleshooting
Weekly or
Troubleshooting
200
> 200
>5
Continuous
0.20
0.35
0.65
Once per shift
20
40
> 40
Preheater
inlet water
Cation
conductivity,
S/cm
Dissolved
oxygen, ppb
(if not
measured at
CPD)
Ammonia
pH
Continuous
Iron, ppm
Weekly
Sodium, ppb
ORP, mV
Troubleshooting
Specific conductivity, S/cm
Total organic Troubleshooting
carbon, ppb
Hardness
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
Immediate
shutdown
Measured
full load
values
3 to 5
> 0.65
Consistent with pH, no limit

9.2 to
< 9.2
9.6
>5
5
4
5
To + 50
10
> 20
4.6 to 6.0
200
> 200
LP drum water effluent (IP and HP economizer and attemperator water influent)
Cation
Continuous
> 0.65
0.20 0.35
0.65
conductivity,
S/cm
Dissolved
Once per shift
1 to 10 15
> 20
20
oxygen, ppb
(if not
measured at
CPD)
pH
Continuous
9.8 to
< 9.8 or > 10.2
< 8.5 or
10.2
>12
Silica, ppb
> 20
10
15
20
Iron, ppb
Weekly
>5
5
0.27 to
0.62
96 to 103
9.8 to 9.9
4 to 7
2-7

Location/
Parameter
Sample
*
*
Troubleshooting
Continuous
Once per day
Weekly
Phenolphthalen alkalinity, ppm

Methyl purple alkalinity, ppm
Hydroxide,
Troubleshooting
ppm
*
*
HP drum water (blowdown or

downcomer)
Cation
Continuous
conductivity,
S/cm
Phosphate,
Once per shift
ppm
pH
Continuous
Sodium, ppm
Silica, ppb
Iron, ppm
Continuous
Once per day
Weekly
Phenolphthalen alkalinity, ppm

Methyl purple alkalinity, ppm
Hydroxide,
Troubleshooting
2-8
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
Immediate
shutdown
Measured
full load
values
2.8 to 4.3
IP drum water (blowdown or

downcomer)
Cation
Continuous
conductivity,
S/cm
Phosphate,
Once per shift
ppm
pH
Continuous
Sodium, ppm
Silica, ppb
Iron, ppm
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
5
Consistent with pH, no limit
Copper, ppb
Ammonia,
ppm
Chlorides,
ppb
ORP, mV
Normal
To + 50
< 1 or > 4
9.2 to 9.6
0.6
5
6
15
0.1 to 4.1
< 9.2
< 8.5 or
>12
>0.6
>5
9.2 to
10.0
7 to 23
1.3 to
17.6
3
< 1 or > 4
9.2 to 9.6
5
6
15
0.1 to 3.8
< 8.5 or
>12
>0.6
>5
9.4
3 to 7

Sample
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
LP drum
saturated
steam
Cation
conductivity,
S/cm
Sodium, ppm
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
Silica, ppb
Once per day
10
20
9.2 to 9.6
40
> 40
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
Once per day
10
20
9.2 to 9.6
40
> 40
Location/
Parameter
Immediate
shutdown
Measured
full load
values
ppm
pH
IP drum
saturated
steam
Cation
conductivity,
S/cm
Sodium, ppm
Silica, ppb
pH
10.2
9.8 to
10.0
HP drum
saturated
steam
Cation
conductivity,
S/cm
Sodium, ppm
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
Silica, ppb
Once per day
10
20
40
> 40
0.55
1.0
> 1.0
pH
9.2 to 9.6
LP superheater outlet steam

Cation
Continuous
conductivity,
S/cm
0.30
0.29 to
0.35
3.3 to
10.7
9.7 to
10.0
2-9

Location/
Parameter
Sample
Normal
Action
Level 1:
Return
to
normal
within 1
wk, No
more
than 2
wk/yr
Action
Level 2:
Return
to
normal
values
within 24
hr, No
more
than 48
hrs/yr
Action
Level 3:
Shut
down unit
within 4
hrs to
avoid
damage,
No more
than 8
hrs/yr
Sodium, ppm
Continuous
10
20
> 20
Silica, ppb
Once per day
10
20
9.2 to 9.6
40
> 40
0.30
0.55
1.0
> 1.0
10
20
> 20
10
20
9.2 to 9.6
40
> 40
pH
IP superheater outlet steam

Cation
Continuous
conductivity,
S/cm
Sodium, ppm Continuous
Silica, ppb
Once per day
pH
HP superheater outlet steam

Cation
Continuous
conductivity,
S/cm
Sodium, ppm Continuous
0.30
0.55
1.0
> 1.0
10
20
> 20
Silica, ppb
pH
Once per day
10
20
9.2 to 9.6
40
> 40
Continuous
0.30
0.55
1.0
> 1.0
Continuous
10
20
> 20
Once per day
10
20
9.2 to 9.6
40
> 40
Reheat
outlet steam
Cation
conductivity,
S/cm
Sodium, ppm
Silica, ppb
pH
Notes:
2-10
* = EPRI "core" parameters

HP/IP/LP drum pressure: 2074 psig/528 psig/ 83 psig
Immediate
shutdown
Measured
full load
values
0.11 to
0.15
0.12

30
Average of 10 daily iron readings in Units #1, #2, and #3
Total iron concentration, ppb
25
20
15
10
IP
#3
H
PE
co
n#
H
1
PE
co
n#
H
2
PE
co
n#
3
H
P#
1
H
P#
2
H
P#
3
IP
#2
IP
#1
LP
#3
LP
#2
on
de
ns
at
e
LP
#1
Figure 2-3
Total (particulate + soluble) iron levels measured in each of three HRSGs after a few
months of plant operation. Note that the iron concentrations are close to the desired value
of less than 5 ppb for all the sections of the cycle except the intermediate pressure drums.
2.2.2 Review of Pre-operational and Layup Practices

The layup practices that have been and will be used should be thoroughly reviewed to identify
opportunities for improvement since poor layup practices can cause severe, rapid and numerous
HRSG pressure part failures.
As part of this review it may also be worth finding out when and how the unit was stored prior to
commercial operation, especially during periods of suspended construction. It is useful to learn
how the final pressure test hydrotest water was treated and how long it remained in the pressure
parts. The pre-operational chemical cleaning reports should be reviewed to learn if the unit
entered commercial operation with clean, well passivated internal surfaces.
One of the wet layup issues that often needs to be thoroughly reviewed and evaluated, especially
for units that experience numerous stop/start cycles, involves the feeding of a reducing agent
such as hydrazine into the water during shutdown periods. The objective of this practice is to
provide a means of controlling the level of dissolved oxygen in the water. Unfortunately this
practice can often make the situation worse because it changes the electrochemistry of the water
sufficiently to alter the stability of the passive oxide layer that has formed on the water touched
2-11

surfaces. Under alternating on-line oxidizing and off line reducing conditions the protective iron
oxides will become non-adherent and during restarts very high concentrations of oxide will
release from the water touched surfaces, flow forward and deposit in the high heat flux sections
of the IP and HP evaporators.
One of the goals of the cycle chemistry program, especially for units that are required to stop and
start frequently should be to condition the water in a way that makes the pH fluctuate as little as
possible and maintains the oxidation-reduction potential (ORP) either positive (oxidizing) or
negative (reducing). If the on-line chemistry requires a reducing (negative) ORP then the off-line
wet layup should also be designed to produce water that is reducing. On the other hand, if the
more desirable practice (for most modern, all-ferrous pressure part HRSGs) of treating the
feedwater with chemicals that produce a positive ORP is used then the wet layup practices
should be designed to produce water that also maintains a positive ORP. The practices to
accomplish these objectives are documented in the EPRI Interim Cycle Chemistry Guidelines1.
EPRI is currently working on a HRSG layup guideline which will provide an update on the best
options for wet and dry layups.
For units that dont use a feedwater reducing agent except for wet layups the feedwater and LP,
IP and HP drum water iron concentrations should be measured during some cold starts that were
preceded by wet layup and starts following extended weekend shutdowns. Grab samples taken
every 15 minutes during the startup will provide a baseline for comparison tests performed using
wet layups that only use a properly applied nitrogen blanket and cycle chemistry that is the same
as the operating chemistry.
This review should also include a detailed evaluation of the nitrogen capping feedpoints, and
practices. A common error is to provide the nitrogen too late (after some air entered the pressure
parts). It is important that the nitrogen cap be added to the main condenser and turbine, deaerator
and storage tank and steam drums while there is still residual heat and pressure present. This
positive pressure of nitrogen must also be maintained throughout the layup period. For wet layup
that last longer than a few days the water in evaporator and economizer circuits may need to be
circulated to avoid prolonged stagnant conditions.
With regard to diagnostic monitoring issues and wet layups some consideration should be given
to instrumentation requirements and sampling intervals to ensure that the pH and oxygen levels
in the economizer, evaporator, condenser and feedwater water are maintained within acceptable
levels. If dry layups are being used then instrumentation requirements for monitoring the
humidity throughout the HRSG, turbine, condenser and feedwater system should be addressed.
2.2.3 Review of Thermal-Mechanical Parameters
The thermal mechanical design and operating practices review can begin in a fashion that is
similar to the cycle chemistry review but usually requires considerably more information and
previous experience analyzing the results from diagnostic monitoring of other HRSGs because
many of the key damage influencing operating targets and control limits are often not known and
the damaging thermal events can be very localized and of short duration.
2-12

The review of steady state operating parameters at full load and at part loads at the lower end of
the normal operating range might occasionally provide some indication of problems in HP
superheater or reheater. However, even when bulk values of economizer approach temperature or
evaporator pinch points are within their expected ranges the unit may still be experiencing
severe, damaging thermal transients because the tube temperature anomalies usually do not cause
discernible deviations in the bulk outlet fluid temperature measurements.
The next step is to review the transient conditions for a broad sampling of shutdowns and
startups. Unless the unit already has definitions for different transients the following definitions
could be used:
The usual shutdown procedure used at the plant
Shutdown with controlled combustion turbine firing
Forced cooling or rapid maintenance shutdown
Trip (Combustion turbine (CT), Steam turbine (ST), or HRSG induced)
Rapid hot restarts - with the unit offline for less than ~ 5 hours
Hot starts made after longer shutdowns where the HP drum pressure prior to the startup
remains above approximately 35 barg (500 psig). These are associated with shutdowns that
are around 5 to 12 hrs, depending on the method used for the shutdown and the leak tightness
of the HP section of the HRSG.
Warm starts made after the HP drum pressure prior to the startup is between approximately 7
barg (100 psig) to 35 barg (500 psig) , provided the unit was boxed up after the shutdown
with high HP drum pressure and is leak tight. These are associated with weekend shutdowns.
Some units will not be able to maintain HP drum pressure above 7 barg (100 psig) for more
than approximately 12 hrs to 24 hrs offline.
Extended warm starts made after the HP drum pressure has approached ambient conditions
(0.5 barg to 7 barg, 7 psig to 100 psig). These are typical of long weekend shutdowns 24 to
60 hours although some units may experience HP drum pressure decay to ambient pressure in
30 hours or less offline. Although rare, some units are able to maintain pressure above
ambient for time periods approaching 72 hrs or more.
Cool starts made from 0 barg (0 psig) pressure, but where the HP drum water temperature
remains above about 75oC (167oF).
Cold starts made after the HP drum water are close to ambient conditions.
Unless a stop/start algorithm has been programmed into the plant historian it will probably only
be practical to review a small number of recent shutdown and startup events.
If the plant historian does not have a software algorithm to identify the date, time, type and
relative severity of the stop/start transient then plots of the following parameters can be used to
quickly identify the beginning and ending date/time of specific shutdowns and startups:
Combustion turbine speed, exhaust temperature, and load
HP drum pressure
2-13

HP steam outlet temperature and pressure
Steam turbine load
The basic thermal cycle comprises a CT/HRSG shutdown, followed by a period of natural
cooling while offload, followed by the CT/HRSG startup and reloading to high load, followed by
the high temperature dwell part of the cycle during operation on load. The beginning of this
thermal cycle is identified by the beginning of combustion turbine load decrease from the highest
operating load. The beginning of the start is identified by the purge conditions (the combustion
turbine speed increases with no load or increase in exhaust gas temperature). The end of the
startup is when the combustion turbine reaches stable load with the HRSG producing steam at
maximum temperature and pressure.
The category of start for the HRSG is determined by the HP drum pressure just prior to the
startup. Figure 2-4 illustrates the constituent parts of one basic thermal cycle. The procedures
used in Figure 2-4 for both the shutdown and startups parts of the cycle are aggressive and
conflict with those recommended in Section 4.3 of Reference 3 and are likely to lead to
premature damage or failure in critical parts of the HRSG if cycled.
Once the time periods of the shutdown and startup phases of a range of thermal cycles have been
identified then more detailed data plots and evaluations for each of these time periods should be
performed. Appendix A list various DCS data attributes that have been found to provide useful
insights into the potential for specific types of thermal-mechanical damage. The reader is
encouraged to start by identifying a pressure part and design feature of concern then identify the
available DCS instrumentation attributes that provide insight about the thermal-mechanical loads
associated with the pressure part feature. Appendix A provides examples of timeline plot
attributes that have been useful for specific components/features.
2-14

2000
HP drum pressure
CT exhaust temp
CT load
200
CT speed
180
160
Shutdown
(1) No controlled cooling (CT speed = 0)
(2) Pressure decay rate (~-1 psi/min)
1400
~ 1-1/2 hr warm start
140
1200
120
1000
100
800
80
Min. HP drum pressure 350 psig
600
60
400
40
200
Load (MW), Speed (%)
1600
Pressure (psig), Temperature ( F)
1800
20
Purge
~16 hrs off line
1440
1320
1200
1080
Time, minutes
960
840
720
600
480
360
240
120
0
0
Figure 2-4
Characterization of an aggressive basic thermal shutdown and startup cycle.
The procedures used for this shutdown are not recommended for units intended for
cycling service. Note that the shutdown was performed with rapid deloading and
shutdown of the combustion turbine (before the superheater headers had been gently
cooled close to the saturation temperature). Next is seen a natural cooling and pressure
decay of the HP drum. This is followed by a short purge signifying the commencement of
the startup (identified by increased combustion turbine speed with a slight decrease in
combustion turbine exhaust temperature and decay in drum pressure) and an
approximately 1-1/2 hr restart. The HP drum pressure decay to approximately 350 psig
(saturation temperature 224oC (435oF)) is within the range characterized as a warm start.
2.3 Step 2: Identifying the Potential Cycle Chemistry or ThermalMechanically Influenced Damage Mechanisms
After completion of the initial review, good engineering judgment is also needed to assess the
potential for damaging thermal-mechanical transients that may not be picked up with existing
instrumentation. Appendix B provides an example of an engineering judgment based preliminary
assessment of a triple pressure, horizontal gas path HRSG with reheat. These judgment based
assessments rely heavily on knowledge and the past experience gleaned from combined cycle
and conventional fossil fuel fired power plant industry experience. Much of this industry
experience information has been widely communicated in public forums and literature. Even so,
it is extremely useful to include an industry expert or two in these reviews.
2-15

The EPRI HRSG Tube Failure Manual2 and the EPRI report on Delivering High Reliability Heat
3
Recovery Steam Generators provide numerous examples of cycle chemistry and thermalmechanical influenced HRSG pressure part failures and the underlying factors that influence
these failures. These references should be thoroughly reviewed to identify potential operational,
maintenance or design features that may be relevant to the unit/pressure part/feature being
assessed.
It has also been found useful with regard to thermal-mechanical influenced damage to review the
loading modes that have been associated with failures. Some of the key loading modes that have
led to pressure part failures have been summarized in the Evaluation and Control of Creep-,
Corrosion- and Thermal Fatigue of HRSG Pressure Parts5 report. These should be reviewed for
each section/pressure part/feature of the HRSG to identify where damage may occur and what
diagnostic/troubleshooting instrumentation is needed to quantify the severity of the loading of
concern.
Appendix B provides an example of the process used to identify potential issues. During this
evaluation every section of the HRSG from the first gas touched tube bundles (e.g., the final
reheater) to the last gas touched tube bundles (e.g., the preheater) should reviewed and assessed.
For each section of the HRSG the following questions should be addressed:
What thermal-mechanical load influenced pressure part failures could occur in this section of
the HRSG or have occurred in units with similar operating, maintenance, or design
attributes?
What thermal-mechanical loads control the potential damage?
What troubleshooting/diagnostic instrumentation is needed to quantify the potential

damaging thermal-mechanical loads and provide the information needed to identify the root
causes of the loads, and verify that corrective actions to eliminate or ameliorate the damage
have been successful?
2.4 Step 3: Specify the Type and Locations for the Diagnostic
Instrumentation
Working with the plant staff, specify the location and type of instrumentation that will need to be
monitored for the cycle chemistry and that will need to be installed for the thermal transient
diagnostic/troubleshooting/improvement tests. In the cycle chemistry area this will also include
grab sampling for iron in the feedwater and evaporator circuits. The specific procedures and
controls to be used prior to and during the operational transients that will be evaluated will also
be defined and communicated.
For example, it may be recommended that some preliminary tests, evaluations and improvement
of the full load chemistry be performed and implemented prior to performing transient thermal
and cycle chemistry tests. These might involve testing oxidation-reduction potential (ORP), feed
and drum water iron level (with and without the feedwater reducing agent) then adjusting
feedwater ammonia level and the drum water solid alkali additives to optimal levels (Figure 2-5).
2-16

20
18
Hydrazine
16
Dissolved Oxygen
ppb
14
Iron Level
12
10
8
6
4
2
7/1/2003
6/30/2003
6/29/2003
6/28/2003
6/27/2003
6/26/2003
6/25/2003
6/24/2003
6/23/2003
6/22/2003
6/21/2003
6/20/2003
6/19/2003
6/18/2003
6/17/2003
6/16/2003
6/15/2003
6/14/2003
6/13/2003
6/12/2003
6/11/2003
6/10/2003
Figure 2-5
Example of a preliminary 21 day in-situ test to confirm that reducing the injection of
hydrazine does reduce the total level of iron in the feedwater. Subsequently on this unit,
the reducing agent was eliminated.
Most of the combined cycle units will have an adequate array of core cycle chemistry monitoring
instrumentation. A listing of cycle chemistry monitoring parameters and monitoring points is
provided in Table 2-2. The core parameters are considered the minimum level of surveillance
that is needed for all HRSG units. In general, use of on-line analyzers for continuous analysis of
chemistry is preferred. However, some provision is made for use of shared instrumentation
(dissolved oxygen) and laboratory analysis of grab samples (silica and phosphate). The
monitoring approaches suggested recognize limitations on manpower at many HRSG plants and
the fact that some analyzers require significant maintenance attention to perform reliably.
The listing of Suggested Additional Monitoring or Diagnostic Parameters indicated in
Table 2-2 represents those chemistry surveillance measures most likely to be included in
customized chemistry programs for specific plants and units. It is anticipated that this existing
instrumentation will need to be supplemented by some grab sampling (particularly of iron).
2-17

Table 2-2
HRSG Cycle Chemistry Monitoring Parameters
Core Monitoring Parameters (Minimum Surveillance for Most Units)
Parameter/Monitoring Approach
Monitoring Points
Cation Conductivity
Continuous by On-Line Analyzer
Specific Conductivity
pH
Continuous On-Line Analyzer
Dissolved Oxygen
(May Be Shared)
Sodium
Phosphate
Grab Sample Analysis Each Shift
(Or Continuous by On-Line Analyzer)
Silica

Condensate Polisher Effluent
Feedwater (or Economizer Inlet)
Blowdown or Downcomer
Saturated Steam, and Main or Hot Reheat Steam
Treated Makeup
Condensate Polisher Effluent (OT)
Blowdown or Downcomer (PT, EPT and CT)
Blowdown or Downcomer (Drum Units)
Feedwater (or Economizer Inlet)
Main or Hot Reheat Steam
Blowdown or Downcomer (PT and EPT)
Treated Makeup
Suggested Additional Monitoring; Troubleshooting or Diagnostic Parameters

Monitoring Points
Specific Conductivity
pH
Sodium
(May Be Shared)
Silica
Grab Sample Analysis Daily
ChlorideGrab Sample Analysis Daily
Sodium Hydroxide
Grab Sample Analysis Daily
(Or Derived from Conductivity Data)
Hydrazine
Iron
Grab Sample Analysis Weekly
ORP
Continuous by On-Line Analyzer (when used)
Total Organic Carbon
Grab Sample Analysis Weekly
Air Inleakage
Check Air Removal Rate Daily
Feedwater (Economizer Inlet)

Condensate Polisher Outlet
Blowdown or Downcomer (PT, EPT and CT)
Saturated Steam
Blowdown or Downcomer
Saturated Steam
Blowdown or Downcomer (EPT, CT, AVT and OT)
Blowdown or Downcomer (CT)

Treated Makeup
Condenser Air Removal System
Still other chemistry parameters that may be monitored under special circumstances include the
following:
Ammonia in Feedwaterto improve control of feedwater treatment or to optimize the

treatment approach.
2-18

Copper in Feedwaterto evaluate feedwater treatment in HRSG units with copper alloys
(HRSG/combined cycles usually have copper-free feedwater systems, but may have copper
alloys in the condenser.).
Sulfate and Chloride in Treated Makeup, Condensate, Condensate Polisher Effluent and
Steamto evaluate cycle contamination and transport involving these species.
Sodium in Treated Makeupto evaluate demineralizer performance.
Total Organic Carbon (TOC) in Feedwater, Boilerwater and Steamto assess the effect of
organic based proprietary treatments and makeup contamination on cycle chemistry.
Analyzers suitable for low level analysis of anions and organics are not expected to be included
in an HRSG plant laboratory. Such testing would need to be contracted to an outside laboratory
with an ion chromatograph (for anions) and a TOC analyzer (for organics).
Water chemistry commissioning should be a part of the total commissioning effort during which
a new unit or a retrofitted unit is transferred from the supplier to the operator. The main
objectives of the commissioning are:
To prevent equipment damage due to malfunction of water chemistry related equipment.
To determine the chemical transport characteristics of the cycle and final selection of water
treatment, water and steam chemistry limits.
To assess major sources of impurities and corrosion.
To quantify total carryover.
This is the primary focus of the monitoring campaigns to be performed within this project to
select the optimum evaporator water and feedwater treatments. There have been too many units
where commissioning has not been performed at all or has been performed insufficiently,
resulting in major equipment damage within weeks or months of the initial operation. Typical
problems that can be avoided by proper commissioning include:
Destruction of the magnetite on HRSG boiler tube surfaces and flow-accelerated corrosion
(FAC).
Severe hideout of water treatment chemicals, such as sodium phosphate, resulting in deposits
and corrosion.
Dryout or onset of departure from nucleate boiling in evaporator tubing which may lead to
overheating or underdeposit corrosion such as caustic gouging, hydrogen damage or acid
phosphate corrosion.
High carryover leading to superheater, reheater, and turbine deposits and superheater and
reheater overheating failures.
Dirt, debris or corrosion products left in the boiler or elsewhere in the system resulting in
buildup of deposits or foreign object damage.
The water chemistry-related systems and functions that should be tested during commissioning
include:
2-19

Choice of boiler water and feedwater treatments.
Chemical oxygen scavenging.
Feedwater corrosion product generation and transport (determination of the points where the
corrosion occurs).
Evaporator carryover.
Chemical addition equipment.
Sampling and analytical equipment.
Deaeration (condenser, deaerator).
Purity of returned condensate.
Blowdown and cycles of concentration.
Makeup system and associated regeneration equipment.
Pretreatment system.
Condensate polishers (if used) and associated regeneration equipment.
Condensate and feedwater storage systems.
Cleanliness and passivation effectiveness after preoperational chemical cleaning of cycle

components.
The importance of comprehensive monitoring/commissioning for all types of HRSGs units and
treatments cannot be overemphasized.
Most combined cycle units will also have an adequate array of core thermal hydraulic monitoring
instrumentation (Table 2-3). It is very likely that additional diagnostic/ troubleshooting
thermocouples will need to be installed. The locations recommended for attachment of
thermocouples to tubes and headers will be based on experience obtained from previous projects
performed on HRSGs with somewhat similar design features in conjunction with the following
general guidelines applicable to horizontal gas path (HGP) HRSGs.
2-20

Table 2-3
HRSG Thermal-Hydraulic Monitoring Parameters
Core Monitoring Parameters (Minimum Surveillance for Most Units)
Monitoring Points
Combustion turbine speed and power output &

estimated exhaust gas flow
Combustion turbine and generator
Combustion turbine exhaust temperature (e.g., grid of

16 thermocouples)
In duct upstream of the HRSG
Duct burner gas flow
Gas inlet pipe
Duct gas temperatures
Upsteam of the HPSH

Upstream of duct burner
Downstream of duct burner
SCR Catalyst Inlet
Upstream of IPSH, HPEcon, LPEvap
Downstream of LP econ or Feedwater heater
Within exhaust stack
Fluid flow rates
HPSH, IPSH/RH, LPSH outlet steam

HP, IP, LP Economizer Inlet
Boiler Feedwater to HP, IP, LP Attemperators
Fluid pressure
HPSH, IPSH/RH, LPSH outlet

HP, IP, LP drum
Deaerator
HP, IP, LP Economizer Inlet
Fluid temperatures
HPSH, IPSH, LPSH, RH outlet header steam

HP, RH desuperheater inlets and outlet
Intermediate HPSH headers
HP, IP, LP Steam drum
HP, IP, LP Economizer outlet
Fluid levels
LP, IP, HP drum levels
Valve positions
Boiler feedwater to HP, IP, LP economizer

position
HP, RH desuperheater valve position
HPSH, IPSH/RH, LPSH bypass valve position
HPSH, IPSH, LPSH vent valve position
Pegging Steam Valve Position
2-21

Suggested Additional Monitoring; Troubleshooting or Diagnostic Parameters
Monitoring Points
Gas temperatures and velocity/ thermocouples
As needed, thermocouples typically attached

to vibration restraint bars
Metal temperatures/surface or buried thermocouples
Selected tubes, header surfaces,

downcomers
Metal temperature gradients/ surface and buried

thermocouples
Selected header outside and near-inside

surfaces (requires a drilled hole), header stub
tube and header outside surface
Pressure drop/ added pressure taps
Locations such as the HP evaporator

downcomers and selected riser tubes
Heat absorption rate/ flux domes, chordal

thermocouples
Typically in sections downstream of duct

burners, HP evaporator, SHs, RHs
Fluid velocity/ annubar flow meters
In HP evaporator downcomers and selected

riser tubes
Dew point meters
Attached to the unfinned tubing at the

feedwater inlet end of the preheater or low
pressure economizer
HPSHs and RHs of all designs of HRSG are vulnerable to damaging tube-to-tube temperature
differences caused by undrained condensate blown forward when significant steam flow is
initiated during each CT/HRSG startup due to one or more of the following design deficiencies:
No means provided to drain condensate from all blind ends of headers, pipes and manifolds.
Drain connections on headers, pipes and manifolds are too small to quickly remove all
condensate during starts from low pressure in HPSH or RH.
Drain pipes and isolating valves are too small.
Drains from different sections of HPSH (or RH) are interconnected with drains from other
sections of HPSH (or RH) that normally operate at different pressures, (instead of each
section that operates at a different pressure being individually piped all the way to the
manifold on the blowdown vessel).
Condensate pools along the bottom of long headers, interconnecting pipes and manifolds
because they were installed with inadequate fall in the direction of normal steam flow in cold
and/or hot operating conditions to ensure all condensate does drain to drain connections.
Inadequate height difference between bottom drain points on HRSG and drain manifold on
the blowdown vessel to accommodate condensate collection pots, positive fall in drain pipes
all the way to the tank, sufficient static head on RH drain lines to provide adequate drain flow
rate from RH when at or close to atmospheric pressure.
Drain flow rates from HPSH drains are not automatically regulated as a function of HP
pressure to prevent excessive HPSH drains flow from overpressurizing the blowdown vessel.
HPSH and RH drains taken to the same blowdown vessel and causing reverse flow of a
mixture of steam and slugs of water from blowdown vessel into RH when simultaneously
draining HPSH and RH.
2-22

Condensation occurs in HPSH tubes whenever the gas temperature at inlet to the HPSH tubes is
below the saturation temperature in the HPSH tubes. This is likely to occur during deceleration
of the CT after firing ceases at every shutdown and in substantial quantities during every prestart
purge before CT firing commences. The second common source of significant quantities of
condensate in HPSH sections is in-leakage of feedwater at interstage desuperheaters due to
leakage past the spraywater control valve when notionally closed if the block valve is open and
the feedpump running, and even past the block valve when notionally closed due to erosion at
the valve seat. When HP superheater pressure is low the high pressure drop across the spraywater
valves when the boiler feedpump is running will pass significant quantities of feedwater through
small leakage paths.
Condensation in RH tubes is most prevalent when cooling during offload periods and during
prestart purges of a cold or cool HRSG with the HP drum at or close to atmospheric pressure.
However, experience from testing several HRSGs installed with TCs on HPSH and RH tubes is
that RH tubes are particularly susceptible to tube-to-tube temperature differences caused by
blowing forward of undrained condensate, not just during cold and cool startups, but also during
hot and warm startups. Furthermore, RH tubes usually experience much larger, very damaging
tube-to-tube temperature differences than HPSH tubes because steam flow and forward pressure
drop cannot be established in the RH until a later stage in the startup than in the HPSH by when
the gas temperature and that of the uncooled tubes is higher. One common sources of undrained
condensate in RHs during startups is in-leakage of attemperator feedwater past passing valves
when the boiler feed pump is running. Another source of potentially substantial quantities of
undrained condensate in the lower manifold, interconnecting pipes and headers of RHs is reverse
flow through the RH drain pipes of substantial quantities of saturated steam, in some cases of
subcooled water, from the common blowdown vessel used for HPSH and RH drains, which
becomes pressurized to above the RH pressure when simultaneously attempting, as necessary, to
drain the HPSH and RH sections prior to establishing forward steam flow through the HPSH and
then the RH. A further source of damage in reheaters is condensate migration forward from cold
reheat pipes when steam flow from the HP steam turbine is established. Substantial condensate
forms during warming from long, large cold reheat pipes between the steam turbine and the
HRSG, and from leakage past eroded seat of the HP bypass attemperator spraywater block
valves, which deficient cold reheat pipe drainage arrangements often cannot quickly remove. An
example of the results from an instrumented RH is shown in Figure 2-6.
2-23

Figure 2-6
Example arrangement of a set of thirteen diagnostic/ troubleshooting thermocouples that
identified and quantified the magnitude of cold startup related row-to-row and element-toelement tube temperature differences in an HRSG reheater bundle. Prior to introducing
steam flow (at approximately 38 minutes after combustion turbine startup) the leading row
tubes (Row A) were approximately 55oC (100oF) hotter than the trailing, Row B tubes. After
introducing steam flow, two of the leading row tubes near the right hand side of the bundle
were rapidly quenched to near the estimated saturation temperature. This forward flow of
saturated liquid (most likely undrained condensate) resulted in a tube to tube temperature
difference near 140oC (250oF). In more recent tests on another design of HRSG tube-to-tube
temperature differences in excess of 167oC (300oF) were recorded.
Significant tube-to-tube temperature differences have been measured in both HPSH and RH
steam heating sections downstream of the desuperheaters during loading ramps at startups and
during deloading ramps at normal shutdowns. The propensity for overspraying is greatest on
HRSGs supplied with exhaust gas from the GE 7/9 FA combustion turbine because of its very
high exhaust gas temperature at relatively low CT generator outputs when steam flow rates are
low. When the HP pressure is simultaneously being raised, which further reduces the HP steam
flow through HPSH and RH, then both HPSH and RH can overspray down to or below
saturation temperature, which results in significant differences across the duct in steam
temperature at tube inlet and outlet of the downstream tube row(s).
Condensate or wet steam cannot be detected in HPSH or RH tubes unless temporary
thermocouples are spot welded to a representative proportion of tubes as illustrated in Figure 2-6.
It is recommended that, where physically accessible, a thermocouple is attached to the top and
2-24

another to the bottom of tubes on the bare section of tubes between the finned tube section and
the header attachment weld behind the gas baffles using the following tube selection criteria:
TCs should be installed on tubes identified by previous testing experience on other HRSGs
with similar tube/header/desuperheater arrangements more susceptible to steam
condition/tube temperature anomalies.
The final steam heating sections of HPSH and RH are particularly susceptible to large tubeto-tube temperature differences and utilize the largest portion of the TCs in the HPSH and
RH sections.
Judicious selection of a few tubes most susceptible to condensate chilling in all earlier
heating sections of HPSH and RH to identify all potential sources of undrained condensate.
Where HPSH and/or RH heating sections downstream of desuperheaters have more than one
parallel-pass rows of tubes, it is important to install TCs on adjacent tubes of all rows
because condensate/wet steam sometimes preferentially flows in tubes of one row.
Tubes closer to the inlet branches on the inlet header of the final heating section of HPSH
and RH are particularly susceptible to chilling by condensate or saturated steam.
Tubes close to the blind end of headers are susceptible to condensate chills by undrained
condensate trapped at the end of the header where there is no local drain connection.
Where the arrangement of inlet and outlet steam pipes results in the tubes across the duct
having different pressure drops, tubes with lower and higher pressure drops need to have
TCs.
Tubes supplied by an inlet pipe downstream of the desuperheater that is closest to the
desuperheater are more susceptible to chills by incompletely flashed desuperheater
spraywater.
Tubes supplied by an inlet pipe downstream of the desuperheater that is furthest from the
desuperheater are more susceptible to chills from excessive quantities of spraywater from
desuperheaters, and also from quenches by undrained condensate.
It is important to install TCs on a proportion of tubes that are expected to be representative of

the tubes not influenced by condensate chills or oversprayed or wet steam.
TCs should be fitted to the top and bottom of a front row and rear row tube and also to the
downcomer of each of the HP, IP and LP evaporator to determine the maximum tube-to-tube and
tube to downcomer temperatures to be accommodated by appropriate flexibility. These
thermocouples will also evaluate the severity of subcooling that occurs in each evaporator during
extended warm shutdowns.
All types of economizer/preheater design have the potential to develop significant thermal
stresses due to tube-to-tube temperature differences. However locations of potential high
thermal stresses associated with tube-to-tube temperature differences is strongly influenced by
the type of economizer design employed. Furthermore, the susceptibility of the particular type of
economizer to significant thermal stresses is also influenced by the extent to which its propensity
to high thermal stresses has been mitigated in the installed detailed design.
2-25

The selection of tubes for installation of thermocouples in HP, IP, LP economizers/preheater

must be tailored to the specific designs installed. An example of thermocouple locations and test
results during a cold start for a vertical tube, final HP economizer with unvented upper return
bends is shown in Figures 2-7 through 2-11. These illustrate the importance of the placement of
the thermocouples. If the only thermocouples installed on this economizer were those located
just below the final outlet header (Location A, Figure 2-7) then the temperatures at Location A
displayed in Figure 2-8 reveal no significant tube temperature abnormalities. However the
thermocouples installed at other locations in this HP economizer (Figures 2-9, 2-10, and 2-11),
highlight significant tube-to-tube temperature differences and that some unvented hairpin bends
are air-locked throughout stable operation over the entire normal operating range of the unit.
Figure 2-7
Example of the location of twenty eight diagnostic/ troubleshooting thermocouples
installed in a vertical tube high pressure economizer tube bundle.
Thermocouples A1, 3, 7, 13, 17, 21 and 23 were installed above the gas seal on the vertical
upflow tubes just beneath the outlet header. Thermocouples B2, 4, 6, 12, 18, 22 and 24
were installed above the gas seal and below (downstream of) the return bend closest to
the outlet. Thermocouples C1, 3, 7, 13, 17, 21 and 23 were located above the gas seal and
below (downstream of) the return bend closest to the inlet. Thermocouples D2, 4, 8, 12, 18,
22 and 24 were located on the vertical downflow tubes just beneath the inlet header and
above the gas seal.
2-26

Figure 2-8
Seven high pressure economizer tube Row A (just beneath the outlet header, see Figure
2-7) thermocouples measurements during a cold start. At this location the measurements
suggest that the HP economizer approach temperature is at least 10oF (6oC) and the tube to
tube temperature differences are less than 25oF (14oC). No steaming or severe tube to tube
temperature differences would be indicated from these thermocouples.
Figure 2-9
Seven high pressure economizer tube Row B (just after the final upper return bend, see
Figure 2-7) thermocouples measurements during a cold start. At this location the
measurements indicate that the water in four of the seven tubes is more than 25oF (14oC)
above the estimated saturation temperature (i.e., air-locking or steaming is occurring in
the tubes near the edges of the bundle). This resulted in a tube to tube temperature
difference near 80oF (44oC).
2-27

Figure 2-10
Seven high pressure economizer tube Row C (just after the first upper return bend, see
Figure 2-7) thermocouples measurements during a cold start. At this location the
measurements indicate that the water in one of the seven tubes is more than 10oF (6oC)
above the estimated saturation temperature (i.e., air-locking or steaming is occurring in at
C23). Since the water in the other tubes is more than 100oF (55oC) below the saturation
temperature this results in a tube to tube temperature difference that is greater than 100oF
(55oC).
2-28

Figure 2-11
Seven high pressure economizer tube Row D (in the vertical downflow tube just beneath
the inlet header, see Figure 2-7) thermocouples measurements during a cold start. At this
location the measurements indicate that the water in the three cooler tubes, which are
probably representative of the majority of tubes in the row, remains close to the HP
economizer feedwater inlet temperature, whereas the fluid in the other tubes with TCs (that
are close to the blind ends of the inlet header and further from the inlet pipes on the
header) operate up to 67oC (120oF) hotter than the coldest tubes due to either flow
stagnation or reverse, recirculating flow upwards in the tubes with the lowest pressure
drop between the upper inlet and lower return header. Lower flow and high temperatures
in the tubes furthest from the inlet pipes were caused by higher hydraulic resistance and
buoyancy forces in the water in these tubes. Gas laning and elevated heat absorption in
the tube circuits near the sides of the bundle may have been partially responsible for the
increased buoyancy forces, reduced flow and elevated water temperature observed.
Appendix B provides additional examples of thermocouple placements for the specific tube
bundle of a horizontal gas path HRSG that has operational and design features that have been
extensively monitored in units of similar design. Drawing from the experience and knowledge
gleaned from the more extensive evaluations of the similar units it was possible to select a
minimum number of locations for diagnostic/troubleshooting thermocouples. For units without
this prior experience more extensive thermocoupling would be needed to ensure that all the
significant and damaging thermal-mechanical loads are identified.
2.5 Step 4: Install High Priority Diagnostic Instrumentation

The installation of required instrumentation such as thermocouples must be carefully planned to
obtain the optimal amount of information from the monitoring program.
Appendix C provides a protocol and information regarding the process to be followed for
installation of thermocouples. The most often used reliable diagnostic/ troubleshooting
2-29

thermocouple type used for measuring tube metal/ fluid temperatures are capacitance discharge
welded directly to the outside surface of unfinned sections of tubing near the headers. These are
attached with the two thermocouple junctions approximately 0.06 in (1.5 mm) apart. This
provides a junction that responds rapidly to fluid temperature changes. The thermocouple
junctions are covered with insulation to ensure that the tube metal/ fluid temperature is being
measured rather than some average tube/gas temperature as would result with uninsulated, pad
type thermocouples.
Special care is required when attaching thermocouples to Grade 91 components. This material is
susceptible to severe hardening during welding and is more sensitive to weld imperfection than
lower alloy materials. A high degree of care should be made to ensure that the surfaces for the
thermocouple junctions are clean, dry and adequately preheated. It is recommended that weld
qualification testing is performed to demonstrate that the capacitance discharge welding process
and procedure produces adequately fused, crack free welds.
2.6 Step 5: Operate Unit over a Wide Range of Operating Conditions

Once the diagnostic/ troubleshooting instrumentation has been installed some thought needs to
be given to data acquisition sampling and storage. Cycle chemistry instrumentation sample
frequency will be very dependent on the specific issues being investigated and no generic
recommendations on sampling frequencies are given here.
Trial and error experience with diagnostic/ troubleshooting thermocouples indicates that a
sample rate of once every 5 seconds is sufficient without creating excessive amounts of data
storage requirements or temperature change events that occur so rapidly that they arent of
practical significance. There are numerous electronic data acquisition and storage systems
available that are adequate for the simultaneous monitoring of many hundreds of thermocouples.
It is important that the data acquisition system date/ time recorder is linked and accurately
synchronized with the existing plant historian instrumentation values so that the results of the
diagnostic/ troubleshooting instrumentation can be used in combination with existing
instrumentation.
Although it is compelling to consider designing and running specific operational tests the
common and more practical approach is to just continue to operate the plant using current
practices and operating regimes to collect a baseline set of data to compare at a later date with
further data obtained after specific corrective actions or operational, maintenance or design
alterations that may be tested.
It is anticipated that some of the cycle chemistry diagnostic tests might need weeks to months to
become established. It may take even longer periods of time before the unit has been cycled
through a representative set of all operating transients. If specific conditions need to be studied
that after some period of time have not been experienced then these tests should be set up such
that they can be performed before thermocouples begin to fail within the limits of commercial
operational restraints on the unit.
2-30

2.7 Step 6: Review and Evaluate the Results of Diagnostic Instrumentation

Measurements
After the unit has operated over a range of representative operating conditions then a thorough
review and evaluation of the monitoring results is needed. These evaluations may involve simple
reviews or may involve additional changes in chemistry or operational procedures and
monitoring campaigns to assess their effects or more complex modeling of thermal conditions,
stress and damage accumulation estimations.
For example, for chemistry tests the EPRI Guidelines(1) will be used as the arbiter. For thermal
hydraulic tests EPRI is currently developing a set of limits and evaluation guidelines. These will
be used to judge if the measured thermal hydraulic values such as tube to header temperature
differentials or tube to tube temperature differences are acceptable or need to be reduced.
With regard to the evaluation of tube thermocouple data it will be important to develop a method
for presenting and studying the data from both time and spatial perspectives. Figure 2-12
provides an example of a time-line plot used to identify and illustrate the time, location and
severity of tube to tube temperature differences. The notes on the plots will require a bit of
detective work but are key to the understanding of the underlying root causes of the undesirable
thermal events.
When a large number of diagnostic thermocouple have been added to a bundle it is often useful
to present this data in a more spatial perspective. A useful method of spatially presenting a time
slice of data is shown in Figure 2-13. The spatial plot is a time slice of a single point in time
from the same event data plotted as temperature versus time shown in Figure 2-12 extracted from
the time period of severe attemperator overspraying when the most severe tube-to-tube
temperature maldistribution occurred.
Three operating procedure actions contributed to the overspraying incident in Figure 2-12. By
observing the impact on attemperator outlet temperature of somewhat different operator actions
during this phase of startup it was possible to determine the relative influence of the three
contributors to the problem, and from this to develop a possible solution. This is an example of
performing a simple special operational test to understand the relative importance of different
contributors to very damaging events and with that knowledge to develop corrective actions that
ameliorate or eliminate the problem.
2-31

Figure 2-12
Time line plot of the bulk temperatures measured up and downstream of a single parallel
pass, two row, vertical tube, finishing (high temperature) reheater during a warm start
made with a low hot reheat steam temperature setpoint4. Two significant temperature
drops were observed. The first occurred soon after steam flow was established through
the reheater bundles and was attributed to forward flow of undrained condensate. The
second event was more severe and was caused by overspraying of the interstage
attemperator too close to saturation temperature. Operating practices that contributed to
the overspraying were substantial lowering of the RH steam outlet temperature setpoint
and excessively aggressive ramping of the CT load and exhaust gas temperature to the
maximum gas temperature. Simultaneous raising of HP pressure exacerbated the severity
of the event. (Source: Reference 4)
2-32

Figure 2-13
Spatial temperature plot of 74 reheater tube thermocouples. This time slice was associated
with the attemperator overspray event shown in Figure 2-12. Some tubes were more than
83oC (150oF) hotter than the adjacent tubes. The tubes near the inlet nozzle centered above
tube element #9 were severely cooled in both tube rows. Near the other inlet nozzles the
dogleg tube row (Row #2) was being cooled well below the straight, leading row of tubing.
(Source: Reference 4)
2.8 Step 7: Evaluate, Engineer and Implement Operational, Maintenance

and Design Enhancements to Ameliorate or Eliminate Damage Influencing
Cycle Chemistry or Thermal-Mechanical Events
After completion of the evaluation of the diagnostic/ troubleshooting instrumentation further
evaluations, special tests and carefully thought out and engineered corrective actions should be
made to ameliorate or eliminate undesirable cycle chemistry or thermal-mechanical events. The
reheater evaluation discussed under Step 6 provides an example where tests can be performed to
verify and prioritize the root causes and possible corrective action to eliminate a potential source
of large, damaging tube-to-tube temperatures at the inlet of the downstream reheater section.
This will also ameliorate the damage in the reheater inlet header at the pipe nozzle and tube
penetrations by the large, rapid temperature downshocks and upshocks that occurred during the
incident. Detailed evaluations and tests performed on this unit revealed that in addition to
ensuring that the hot reheat steam temperature setpoint was not reduced much below its 566oC
(1050oF) design limit, that the crossover piping between the primary (low temperature) and
secondary (high temperature) reheater should be modified to provide the length needed for
proper mixing of the attemperator water with the steam.
2-33

It has generally been found that optimizing the operational procedures to minimize the problems
should be done before more expensive design alterations are considered. After corrective actions
are made additional tests should be performed to determine the benefit of operational changes. In
addition the role of maintenance activities should not be overlooked. Two maintenance issues
that should be given attention with regard to prevention of undesirable thermal events are the
inspection and refurbishment of drain lines, and maintenance of attemperators and their thermal
shields and block valves.
2.9 Step 8: Verify the Success of the Changes through Additional

Monitoring and Evaluation
It is important to confirm the corrective actions have been successful. If equipment or
maintenance practice modifications are made to the unit then a review the relevant
instrumentation readings before and after the change was made should be made to verify that the
desired objective was achieved. This confirmation can be made by additional diagnostic
troubleshooting monitoring. Corrective actions may need to be performed incrementally to study
and determine optimal and acceptable limits of operation and the impact of the actions on other
plant attributes and components. For example there may be environmental or code compliance
issues that limit the extent to which problems can be addressed by operational changes.
2.10 Step 9: Ongoing Monitoring, Evaluation, and Improvements

One of the key characteristics of world class HRSG pressure part failure prevention programs is
ongoing vigilance and a continuous desire to identify potential problems before they lead to
irreversible damage. One of the primary objectives of diagnostic/troubleshooting monitoring is to
identify precursors or evidence of potential damaging events before they lead cause significant
damage. Regular checkups and critical reviews of operational, maintenance and design issues are
an important part of failure prevention programs. So periodically you should go back to Step 1
and update each of the previous eight steps.
2-34
3
REFERENCES
1. a) Interim Cycle Chemistry Guidelines for Combined Cycle Heat Recovery Steam
Generators (HRSGs). EPRI, Palo Alto, CA., TR-110051, Nov 1998
b) The first revision of this guideline will be published at the end of 2005 as: EPRI, Palo
Alto, CA, 1010438
2. Heat Recovery Steam Generator Tube Failure Manual, EPRI, Palo Alto, CA, TR-1004503,
Nov 2002
3. Delivering High Reliability Heat Recovery Steam Generators EPRI, Palo Alto, CA: TR1004240, Mar 2003
4.
Anderson, R. and M. Pearson, Quantifying Thermal Transients in Heat Recovery Steam

Generators, EPRI Boiler Tube and HRSG Tube Failures and Inspections International
Conference, San Diego, CA. , Nov 2004
5.
Evaluation and Control of Creep-, Corrosion- and Thermal Fatigue of HRSG Pressure Parts,
EPRI, Palo Alto, CA, Mar 2005, 1008090
6.
R.B. Dooley, and R. Tilley, Tube Failures in Conventional Boilers and Combined Cycle/
HRSGs, International Conference on BTF and HTF and Inspections, San Diego, CA, Nov
2004. Published in PowerPlant Chemistry, 2004, 4(12)
7.
R.B. Dooley, S. Paterson and M. Pearson, HRSG Dependability, PowerPlant Chemistry,

2003, 5(12)
3-1
A
BACKGROUND INFORMATION REVIEW
Prior to performing detailed assessments of a given unit it is useful to thoroughly review existing
background information. Some key information that should be included in the review includes
the following:
General Plant/Unit Information
A general description of the combined cycle plant (combustion turbine, HRSG and steam
turbine make and model).
A description of the HRSG influencing thermal systems (e.g., combustion turbine exhaust
gas temperature and flow characteristics, duct/damper/stack system, tube bundle/ header/
drum/piping/ vent/drain/ layouts, attemperator, valve, pump and instrumentation locations).
Steam conditions required for steam turbine startup from different initial condition including
maximum steam to metal mismatches and recommended steam temperature ramp rates, hold
points and durations.
Sectional arrangement drawings of HRSG pressure parts and interconnecting pipes, vents,
drains, including vertical cross section through gas duct between inlet duct and stack, vertical
front view drawings of each heat transfer panel, and plan views at different elevations.
A description of the historical and desired operational/maintenance/reliability attributes of

the unit including (i) a description of the past operating history (i.e., unfired base load
operating hours, fired base load operating hours, low load conditions and hours, out of
service hours, number of startups/shutdowns or if possible the number of cold, warm, hot
starts and the number of normal, rapid and trip shutdowns) and (ii) a description of the
anticipated/forecast operating characteristics (e.g., anticipated total years of service, number
of cold, warm, hot starts per week, month, or year, fired hours per year, unfired hours per
year, out of service hours per year, low load conditions, etc.)
Piping & instrumentation diagrams for HRSG steam and water circuits, cold and hot reheat
steam pipes to steam turbine, high pressure and hot reheat steam bypass/dump systems, high
pressure superheater and reheater drains, etc.
Heat balance diagrams for each fuel, at baseload and part loads for range of ambient
conditions
Sectional arrangement sideviews, plan and front views of the HRSG, showing external
interconnecting pipes, principal valves, attemperators, pipe drain points, superheater and
reheater drain points and pipes and valves to blowdown vessel, etc.
History of any major design modifications or operating procedure changes

A-1

Background Information Review
History of any HRSG failures and the corresponding failure analysis and/or root cause
reports
Cycle Chemistry Information
The general layout and description of the cycle chemistry features of the unit: e.g., makeup/
return condensate characteristics, fluid circuitry, locations of existing instrumentation, typical
operating values of the continuously monitored chemical parameters around the cycle,
locations of chemical feeds, description of feedwater and evaporator water chemical
additives; with all information displayed on a cycle chemistry diagram. Any ancillary
information about the cycle chemistry will also be needed. In this category the levels of iron
at various points (feedwater, evaporator drums) is key to the initial assessment.
A selected history of cycle chemistry records (on-line and grab sample reports), ish needed to
confirm deficiencies or other significant findings of the cycle chemistry diagram compilation.
This should include: (i) printouts of most recent half dozen grab sample results (if
measurements were made on site and by on off site laboratory then evaluate both) and (ii)
printouts of the on-line measured cycle chemistry for the same time periods as the grab
samples plus a printout for selected full load operating conditions including the most recent
full load operating period.
Thermal Cycling Information
The combustion turbine exhaust gas characteristics during startups and shutdowns and over
the full range of operation
The combustion turbine and auxiliary burner fuel characteristics
Currently used operating practices, limits and controls for startup and shutdown of the lead
and lag units
DCS instrumentation list
Side and front views of each section of the HRSG showing the tube to header configurations,
number of tube bundles, materials lists, thickness, diameter, baffle plates, vents, drains,
headers, supports and clearances
Details of tube to header weld preps in each section of the HRSG
Details of thickness and diameter of all headers
Any design or other calculations that address the cyclic life of any HRSG pressure part
Detailed arrangement drawings of the drain systems all the way to the blowdown
DCS historian electronic records plotted versus time (using 5 second time intervals) of key
parameters such as those in Table A-1 for wide range of operating transients (see Section
2.2.3).
For most parameters the plots should be based on the measured median value of the
parameter for 5 second time intervals. For attributes such as combustion and steam turbine
output (MW) or fuel consumed the cumulative values should be used.
A-2

When creating plots of ramp rates the following relationship has been found to produce
meaningful estimation of the ramp rates that have a sufficient duration to produce damaging
temperature gradients through the thickness of the pressure parts being assessed.
dT/dt = (Ti Ti-10)/10 minutes
(A-1)
Where:
dT/dt = Rate of change of temperature (oF/min or oC/min)
Ti = measured temperature at the current time
Ti-10 = measured temperature 10 minutes earlier
Table A-1
DCS Attribute Grouping Useful for Identifying and Characterizing Thermal-mechanical Cycles
Location
Overall unit
characteristics
Combustion
turbine
Attributes for timeline plots

Speed
Output (MW)
Exhaust flow, averaged exhaust temperature
IGV position
Overall unit
characteristics
Key HRSG
Attributes
Duct burner total fuel flow rate

HP drum pressure
Averaged duct gas temperatures
Outlet fluid temperatures, pressures and flows in
each section of the HRSG
HP startup vent position
HP bypass PCV position.
Speed
Output (MW)
First stage metal temperature
Position of HP and IP steam inlet control valve
positions
Steam inlet temperatures at the HP inlet and
steam chest, and IP inlet and steam chest
HP turbine exhaust steam temperature, flow and
pressure
Average CT exhaust temperature
Outlet steam temperature
Outlet steam temperature setpoint for
attemperator control
Interstage attemperator inlet/outlet temperatures
Steam pressure
Steam flow
Spraywater TCV position and spraywater flow
Overall unit
characteristics
Steam turbine
HP superheater
Comments
These plots can be used to
identify the beginning of
shutdowns, the prestart purge,
the end of startups and a
multitude of key characteristics of
the stop/start cycles
May be useful to add a curve for

the estimated saturation
temperature based on measured
pressure
A-3

Location
HP superheater
ramp rate plots
Reheaters
Reheater ramp
rates
HP evaporator
HP evaporator
ramp rates
LP/IP/HP
Economizer/
Preheater
Attributes for timeline plots

Rate of change of:
Outlet steam temperature
Interstage attemperator inlet/ outlet temperatures
Cold reheat steam flow, pressure and
temperature at reheater inlet
IP superheater outlet steam flow, pressure and
temperature
Reheater outlet steam flow, pressure and
temperature
Reheater outlet steam temperature setpoint for
attemperator control
HP bypass inlet flow and PVC position
HRH startup vent position, dump PCV position
Interstage, cold reheat, IP superheater outlet and
HP turbine bypass attemperator spraywater flow,
TCV position, discharge pressure and inlet/outlet
temperatures
Rate of change of:
Inlet steam temperature entering primary RH
Interstage attemperator inlet/ outlet temperatures
Hot reheat outlet steam temperature
Average duct gas temperatures at the nearest up
and downstream positions
HP drum metal temperature measured at the top
and bottom of the drum (if available)
Estimated or measured drum water temperature
HP economizer outlet flow
HP economizer outlet temperature
Drum pressure
Saturated steam flow out of drum
Drum level
HP drum pressure gradient (bar/min, psi/min)
HP drum estimated water saturation temperature
(or preferably the measured water temperature)
ramp rate (oC/min, oF/min)
LP condensate temperature before tempering

with recirculation flow
LP economizer/preheater recirculation flow and
temperature
LP/IP/HP economizer inlet flow, pressure, and
temperature.
LP/IP/HP economizer outlet water temperature
LP/IP/HP Evaporator drum level
Comments
Identify temperature hold periods
by viewing the ramp rate plot in
conjunction with the timeline plot
of the same attributes.
May be useful to add a curve for
the estimated saturation
temperature based on measured
pressure
Use separate plots for
temperatures, pressures, flows,
and valve positions

conjunction with time timeline
plot of the same attributes
The measured ramp rates should

be plotted on a chart that also
includes the maximum allowable
ramp rates.
conjunction with time timeline
plot of the same attributes
Use multiple plots of like
attributes for each economizer
Plots of DCS parameters should be assessed to determine if optimal shutdown and startup
procedures are being used. Discussions with the plant operators and input from individuals well
A-4

versed in design of HRSG operational procedures should be included in this review. A few of the
key questions which should be addressed include:
During shutdowns are the combustion turbine exhaust temperatures being controlled to
values near the estimated high pressure superheater steam saturation temperature so that
severe tube to header and condensate quenching of the lower headers are avoided?
During startups are the HRSGs being provided with an initial heat soak with the combustion
turbine exhaust temperature being held at a minimum achievable value (~ 315oC (600oF) to
360oC (700oF)) to minimize the peak tube to header temperature differences?
During startups are the hold durations and ramp rates from the initial saturation temperature
to full load conditions within acceptable ranges for the HP drum and HP superheater
headers? Has the acceptable ramp rate limits been determined for the HPSH?
During startups or shutdowns are the high pressure superheater, and hot reheat steam outlet
setpoints being manually reduced to temperature values well below the design setpoint (avoid
over temperature trips) thus increasing the potential for attemperator overspraying and severe
tube to tube temperature differences.
Are the HP superheater and reheat bypass steam flows during hot and warm starts being
established at the same time as the combustion turbine startup to provide beneficial cooling
steam to the superheater and reheater tubing?
Detailed evaluation of the timeline plots may identify gross operational or design deficiencies or
opportunities for improvement. In a small number of cases they will provide sufficient
information to identify and correct issues that are damaging to HRSG pressure parts such as
significant attemperator overspraying events. On the other hand, these bulk measurements
cannot be used as confirmation that all is well and that no localized and damaging thermalmechanical issues are active. The underlying conditions that are creating the damaging loads for
the majority of thermal-mechanically influenced HRSG pressure part failures cannot be
identified with the conventional DCS parameters. In most cases tube, pipe, and header metal
temperature measurements are required to identify the damaging events and root causes and to
provide verification of the success of corrective actions.
A-5
B
IDENTIFYING POTENTIAL DAMAGE MECHANISMS
AND DIAGNOSTIC MONITORING NEEDS
After completing the background review it is necessary to identify potential problems and
damage mechanisms. Once the high priority potential issues and damage mechanisms are
identified then the diagnostic monitoring instrumentation and attachment locations can be
prescribed. This appendix provides an example of this phase on a triple-pressure horizontal gas
path HRSG.
Some of the guiding principles that are followed with regard to this monitoring are:
Bulk fluid temperatures will, in general, not be adequate to identify and quantify the severity
of the thermal transients that have been responsible for failures.
Severe thermal transients resulting from quenching of a few tubes within a superheater or
reheater tube bundle with attemperator spraywater or undrained condensate, etc., or chilling
of a few tubes in the feedwater inlet row of LP economizes/preheaters, which has been
responsible for numerous tube to header or drain to header fatigue failures, cannot be
detected or quantified unless thermocouples are bonded to many of the tubes to determine the
tube-to-tube and tube-to-header temperature differences.
Transient temperature differences between tube rows and downcomers of evaporators that
occur when establishing circulation cannot be detected or quantified unless thermocouples
are bonded to several tubes and pipes of the evaporators. These have been responsible for
failures in evaporator pressure parts.
Fast response thermocouples, with their junction attached directly to the tube (not the welded
sheath type connection) have been successful in measuring the damaging transients on
several designs of HRSG.
Damaging thermal transients in tube bundles are cause by a combination of the occurrence of
significant transient tube-to-tube temperature anomalies in conjunction with pressure part
design features that locally intensify the resulting thermal forces and stresses. Thus the
selection of thermocouple locations requires:
A thorough review of the design, arrangement and support of tubes and headers, of
interconnecting pipes and locations of header nozzles in each section of the HRSG; and
additionally of the location of drains on the headers, pipes and manifolds, and of
attemperators in superheater and reheater sections, of tube bundles and interconnecting
pipe flexibility, and of venting in economizers and preheaters, recirculation arrangements
for preheaters, etc.
B-1

Identifying Potential Damage Mechanisms and Diagnostic Monitoring Needs
A review of DCS time line plots to identify potentially damaging conditions during
startups from different initial conditions, during stable on-load operation and during
shutdowns.
Knowledge of the types of thermal-mechanical loads that may lead to fatigue damage in
specific tube bundles. Some guidance is provided in Chapters 4 and 7 of Reference 3 and
in Reference 5. Other types of thermal-mechanical loading mechanisms have been
identified in more recent analysis of results from diagnostic monitoring.
Personnel Involved
A cursory review of plant information should be performed prior to an on-site working meeting.
Once this is completed then a one day on-site working meeting should be sufficient to complete
the Phase II activities. To be effective, the following individuals, as a minimum, should be
involved with the unit reviews and decisions regarding the extent and specific installation
locations of diagnostic instrumentation to be added to the unit:
Plant Manager
Plant Operator
Plant Engineer
Maintenance Superintendent
Corporate Chemist
Senior Lab Technician
A consultant with extensive experience in HRSG cycle chemistry issues and solutions
A consultant with extensive experience in HRSG operation, design and diagnostic

monitoring
A consultant with extensive experience in HRSG thermal mechanical damage mechanisms

and metallurgy
Objectives
The following are the objectives of these reviews:
Identify major potential issues of concern:

Cycle chemistry influenced
Thermal-mechanical
Develop action plans

To determine which potential issues are significant and need corrective action
To develop a baseline set of and diagnostic/troubleshooting information/ instrumentation

data so that appropriate corrective actions can be developed to eliminate or ameliorate
those issues that are confirmed to be significant
B-2

Approximately 5 hours of review are required with the consultants, the plant engineer and the
corporate chemist performing walkdowns of the unit, reviewing specific cycle chemistry, plant
historian data, and tube bundle drawings and discussing potential issues of concern. The results
of this effort are summarized as follows:
Cycle Chemistry Issues of Concern
Phosphate hideout in HP evaporator
Recommended actions:
Phosphate hideout in HP evaporator
Ongoing phosphate/pH/conductivity monitoring of the HP drum water
Videoprobe examination of leading row HP evaporator tubes
Review of gas temperature profile, circulation ratio at various fired and unfired
operating conditions
High (~10 ppb) iron levels in IP systems (If a feedwater reducing agent was not used, then the
concern here would be for two-phase flow accelerated corrosion)
Recommended actions:
Ongoing iron monitoring including some detailed monitoring performed during thermal
transients and following IP drum blowdown
Visual inspection (partially augmented with videoprobe) of drums and selected

headers/tubes
Priority Thermal-mechanical Issues of Concern
Final (high temperature) reheater tube bundle (RH2)
Thermal/creep fatigue at tube to header connections and boreholes due to forward flow of
condensate/leaking or excessive attemperator spraywater into row 1 or 2 (the
attemperator was located between RH1 and RH2 near the top of the unit)
Non-uniform inlet steam temperature
Elevated steady state outlet temperature in row 1 at part load
<5 year issue

Actions:
Install thermocouples on tubes on selected tubes near the lower (inlet) and (upper)
outlet headers
Determine safe limits/cyclic life
Review drain valve operation
Essential to maintain tight shutoff on interstage attemperator spray water block valve.
If impractical consider addition of a second master block valve
Videoprobe examination of headers
B-3

Final (high temperature) high pressure superheater bundle (HPSH2) (two sequential pass
tubes with 2.5-inch (6.35 cm) thick outlet header constructed in P91)
High tube to header temperature gradient (potential for cracking in boreholes and tube to
header welds) due to excessive steam pressure/temperature ramp rates (may need to severely
restrict ramping to ameliorate damage rate)
5 to 10 year issue
Actions:
Need to determine what ramp rate and temperature gradients are acceptable
Tube to header connection thermal or creep fatigue due to forward flow of undrained
condensate during startup
5 to 10 year issue
Actions:
Review drain operating logic for various transients
Install thermocouples on selected tubes to verify complete draining of condensate; if not
modify design and/or operation to eliminate forward condensate migration
Overspraying of attemperator water into selected tubes (interstage attemperator located at

top of unit)
< 5 year issue

Actions:
Maintain leak tight attemperator block valves
If necessary, modify operation during startups and shutdowns to lower gas and steam
temperature ramp rates when gas temperatures highest, maintain high RH outlet steam
temperature setpoints for attemperator control, avoid pressure ramping when approaching
maximum CT exhaust temperature conditions.
Videoprobe examination of final reheater inlet headers at the intersection of inlet pipe
nozzles and tubeholes with header bore
Primary (low temperature) reheater (RH1:Two parallel passes of 2 sequential row of tubes, 4
tube rows just downstream of duct burners, 377oC (712oF) inlet steam/ 555oC (1038oF) outlet
steam with duct burner)
Accelerated creep due to duct burner heat maldistribution, heat transfer above design
Creep/ fatigue at tube to outlet header connections due to high temperature rise through RH1
tubes at steady state/ duct firing
Tube to outlet header or tube to tube temperature differences caused by condensate migration
from cold reheat pipes or leaking HP turbine bypass attemperator water
B-4

Thermal fatigue at the tube to inlet header connections due to first admission of HP bypass
exhaust steam into the hot reheater tubes and cold headers and/or condensate or leaking HP
turbine bypass attemperator water
<5 year issue

Actions:
Install thermocouples on tubes on selected lower (inlet) and (upper) outlet header
Determine safe limits/cyclic life (consider the benefit of header spring supports)
Review startup and shutdown procedures with regard to HP bypass attemperation and RH
venting
Review drain valve operation
Essential to maintain tight shutoff on HP bypass spray water block valve. If impractical
consider addition of a second master block valve
Review reliability of drain on cold reheat pipe on HRSG side of CRH isolation valve and
consider whether drip pot would improve reliability of condensate removal
Primary (low temperature) high pressure superheater (HPSH1)
Thermal/creep fatigue at tube to outlet header connection caused by forward flow of

undrained condensate during startup
> 10 year issue

Actions:
Ensure correct drain operation
Backflow of leaking attemperator water at low steam flow conditions during shutdowns or
starts
1 to 5 year issue
Actions:
Maintain leak tight attemperator block valves
Determine and control the gas temperature/fluid temperature/fluid flow v. attemperator
block valve control (highest risk during shutdown)
HP Evaporator
Drum and lower header connection (nozzles/tube to header/interconnect piping) thermal

fatigue due to excessive fluid ramp rates
Unanticipated riser tube to downcomer temperature differences
Unanticipated riser tube-to-tube temperature differences when establishing natural circulation
Stratification of subcooled water during long weekend shutdowns
<5 year issue

B-5

Actions:
Perform analysis to determine safe limits/ cyclic life
Install thermocouples on top & bottom of each downcomer and 1st and last row riser
tubes
Prepare and use ramp rate monitoring system
High deposition and underdeposit corrosion due to local steam films in leading row during
duct firing
<5 year issue

Actions:
Shift cycle chemistry to maintain HP drum water iron concentrations to less than 5ppb
Install chordal thermocouples near top of leading row tubes
All Economizers and Preheater tube bundles
Thermal/corrosion fatigue at upper return bends and tube to header welds due to water
leaking from inlet leg drains and back into hot legs of economizer
Air- and/or vapor-locks at some upper bends causing stagnant flow in some tubes (especially
in the final high pressure economizer)
Chilling of inlet tubes rows of preheater by introduction of cold feedwater into hot tubes
/headers during startup
< 5 year issues

Actions:
Modify drains with double isolation of each row of bottom headers
Ensure correct operation of each drain valve pair by designating one as the master and the
other as the martyr (open master 1st, close master last)
Avoid operation at low feedwater flow rates
Modify preheater recirculation system (i.e., evaluate the need for a larger pump) to
temper the inlet feedwater during startup
The thermal mechanical issues that were selected for further diagnostic instrumentation study
with were:
Gas/ tube temperature maldistributions during low load and duct firing
Temperature ramp rate issues in the high pressure superheater and high pressure evaporator
Forward flow of condensate (either formed during pipe warming or from leaking HP bypass
attemperator spraywater) from cold reheat pipes into the downstream reheater tubes
Forward flow of undrained condensate or attemperator spray water into selective high
pressure superheater tubes
B-6

Forward flow of undrained condensate or attemperator spray water into selective reheater
tubes
Table B-1 and Figures B-1 through B-5 document the locations where diagnostic thermocouples
were specified.
Table B-1
Location and Number of Diagnostic Thermocouples
Location
Number of
thermocouples
RH2 outlet vestibule tubes
32
Comments
Tube bundle A: 5 element x 2 rows x top & bottom of
each row
Tube bundle B: 3 element x 2 rows x top & bottom of
each row
HPSH2 tubes
14
Tube bundle A: 7 elements x top & bottom of gas inlet row
RH1 (tubes near

intermediate header)
18
Tube bundle A: 6 elements x top& bottom of gas inlet row
HP evaporator
Tube bundle B: 3 elements x 2 rows x top & bottom of gas

inlet row
Top, 1/3 height and bottom of one downcomer
2 elements x top & bottom of leading row
1 element x top & bottom of trailing row
Preheater
15
5 elements x top & bottom of water feed inlet row and in

the next row just below the 1st upper return bend
B-7

Reheater #2:
RH2_T3
RH2_T4
RH2_T1
Thermocouples placed
between the header and
finned section of tubing on
the top and bottom of both
tube rows
RH2_T2
Gas Flow (towards south)

West
side
64
55
46 45
33 32
13
East
side
1
Figure B-1
Location of thirty two thermcouples to be installed in direct contact with the tube OD
surface between the finned tubing and the headers (Tube bundle A: 5 elements x 2 rows x
top & bottom = 20 thermocouples, Tube bundle B: 3 elements x 2 rows x top & bottom = 12
thermocouples).
Due to the stiff, parallel flow reheater bundle design, (with two rows of tubes connected to
a single inlet (bottom) and a single outlet header and dogleg bends) it was decided that the
top and bottom of each row of tubing should be instrumented. This instrumentation
configuration provides an optimal setup to identify severe events involving either forward
flow of undrained condensate or excessive attemperator flow into either of the two parallel
tube rows. The tube elements selected were based on identifying those elements with the
greatest potential to become selectively quenched by undrained condensate or excessive,
poorly distributed attemperator water, plus at least one tube element which is likely to be
representative of the temperature of most of the tubes. Each lower header has two 2-inch
(5 cm) NPS drains connected together into a 2-inch (5 cm) NPS line with the drains from
the second tube bundle. With the unit off-line the drain line gently sloped downward to an
atmospheric blowdown reservoir.
B-8

HP superheater #2:
the top and bottom of the
gas inlet tube row
HPSH2_T2
HPSH2_T1
West
side
East
side
Flow (towards south)

Top, Outlet
Top, Inlet
Bottom, Outlet
35
27 22 21 16
Bottom, Inlet
Figure B-2
Location of fourteen thermocouples to be installed in direct contact with the tube OD
surface between the finned tubing and the headers (Tube bundle A: 7 elements x leading
row x top & bottom = 14 thermocouples, Tube bundle B: none).
Due to the single tube circuit design, it was decided that the top and bottom of the leading
tube row should be instrumented. These pairs of thermocouples will identify and quantify
the severity of significant forward flow of undrained condensate and/or excessive
interstage attemperator flow being introduced into the inlet row tubes. The tube elements
selected were based on identifying those elements with the greatest potential to become
selectively quenched by undrained condensate or excessive, poorly distributed
attemperator water, plus at least one tube element which is likely to be representative of
the temperature of most of the tubes. Each lower header has a single 2-inch (5 cm) drain
connected together into a 2-inch (5 cm) line with the drains from the second tube bundle.
With the unit off-line the drain line gently sloped downward to an atmospheric blowdown
reservoir.
B-9

Reheater #1:
gas inlet tube row
RH1_T2
RH1_T1

West
side
63
East
side
54
48
31
24
17 16
Figure B-3
Location of eighteen thermocouples to be installed in direct contact with the tube OD
surface between the finned tubing and the headers (Tube bundle A (duct burner fuel inlet
supply side of unit): 6 elements x gas inlet row x top & bottom = 12 thermocouples, Tube
bundle B: 3 elements x gas inlet row x top & bottom = 6 thermocouples).
Even though this reheater has a parallel circuit configuration, due to the row to row
flexibility of this reheater bundle design, it was decided that only the top and bottom of the
leading tube row should be instrumented. Previous experience with similar designs had
found that the longer, circuit with the larger diameter lower header had the greatest
potential to experience severe thermal quench events due to either undrained condensate
or introduction of excessive attemperator spray into the cold reheat piping system. The
tube elements selected were based on identifying those elements with the greatest
potential to become selectively flooded with undrained condensate or excessive, poorly
distributed attemperator water, plus a few tube elements which are likely to be
representative of the temperature of most of the tubes.Each lower header has one 2-inch
(5 cm) drain connected together into a 2-inch (5 cm) line with the drain from the second
tube bundle. With the unit off-line the drain line gently sloped downward to an
atmospheric blowdown reservoir
B-10

HP Evaporator :
To HP Evaporator
Remote Steam Drum
IPSH (Elements 1, 3, , 35)
HPEvap_T3
HPEvap_T1
West
side
HPEvap_T4
HPEvap_T2
between the header
and finned section of
tubing on the top and
bottom of the gas inlet
tube row and gas
outlet row and at the
top, bottom and 1/3
height position on the
east-most downcomer
pipe
8 4
East
side
Top
1/3 from
bottom
Bottom
Figure B-4
Location of three thermocouples to be installed in direct contact with the OD surface of
the downcomer on the east tube bundle (One near the top of the downcomer, one near the
bottom of the downcomer, one located 1/3 of the way up the downcomer and 6
thermcouples to be installed in direct contact with the tube OD surface between the finned
tubing and the headers (at the top and bottom of the gas inlet row on elements 4 and 8 and
at the top and bottom of the gas outlet row on element 4)).
The purposes of the HP evaporator thermocouples are to determine if subcooled water
stratifies to the lower portion of the evaporator during long weekend shutdowns, also
whether the rear row tubes transiently act as downcomers or stagnate and overheat when
recirculation is being established, resulting in unanticipated thermal transients when
natural circulation begins during the startups from different initial conditions.
B-11

LP Preheater:
LPEcon_T3
between the header and 1st
upper return bend and
feedwater inlet tube rows
LPEcon_T1
LPEcon_T2
West
side
East
side
Outlet nozzle
19
Inlet nozzle
13
Figure B-5
Location of fifteen thermocouples to be installed in Bundle A in direct contact with the
tube OD surface between the finned tubing at three locations on 5 tube elements, i.e., one
close to the upper feedwater inlet header, another at the bottom of the inlet row tube near
the first lower return header and the third just below the first (in direction of feedwater
flow) upper return hairpin bend; 3 thermocouples on each of 5 elements = 15
thermocouples.
Thermocouples were located to evaluate: (i) introduction of cold feedwater into hot tubes,
(ii) steaming and/or air blockage in upper return bends, (iii) gas laning along edges of
preheater tube bundles, (iv) introduction of hot recirculation water into cool feedwater inlet
row tubes after forward flow is interrupted.
B-12
C
MONITORING GAS, FLUID, AND TUBE METAL
TEMPERATURES
The accurate determination of transient temperature distributions in tubes and headers is critical
to the accurate determination of remaining tube, pipe or header life and for root cause
investigations of pressure part failures. Methods can be either direct, primarily thermocoupling,
which provides current temperature levels, or indirect.
In some cases, existing measurements of bulk steam conditions will provide the necessary
temperature information. For example, the measured steam temperature out of the superheater
bundle just downstream of the duct burners will provide an indication of burner overfiring or
increased gas temperatures due to operating the gas turbine at part load or with the diverter
damper partially open. Also gross overspraying at attemperators is evident from the
measurement of bulk steam temperature at superheater or reheater attemperator outlets. Gross
condensate migration is sometimes, but not always, evident from bulk steam temperature
measurements.
However, to detect and quantify significant temperature differences between tubes intended by
design to always operate at closely similar temperature or to measure the potentially damaging
transient temperature gradients at tubehole and pipe penetrations of thicker headers and pipes,
additional thermocouples must be installed.
Thermocouples bonded to selected tubes are the only sure, proven means of detection of
transiently abnormal conditions, such as steaming in notionally water-wetted tubes or condensate
migration through and downshocking of superheater or reheater tubes associated with specific
operating conditions (i.e., normal load, low loads, transients, etc.). In most cases, the
thermocouples will probably need to be installed in the heat absorbing sections of the HRSG
tubing. To obtain accurate temperature measurements in these locations requires careful
thermocouple installation methods.
Various methods have been attempted for attaching thermocouples to the outer surfaces of bare
sections of tubes, with differing degrees of success. Experience with earlier attempts to measure
the bare surface temperature of tubes by clamped on thermocouples was unacceptable because
the temperatures measured by the clamped on thermocouples tended to be inconsistent
(increasingly so with time as clamps relaxed and surface oxides developed) and more susceptible
to the influence of gas temperature. Thus clamping of thermocouples to the surface of tubes is
not recommended.
Two methods that establish a positive bond between the thermocouple and tube or header surface
have been successfully used. The more durable method of these utilizes sheathed thermocouples
C-1

Monitoring Gas, Fluid, and Tube Metal Temperatures
and bonds the thermocouple sheath to the header or tube surface with a sprayed aluminum
deposit. However this process is more costly and cannot be used on less accessible tube rows.
Also, thermocouples bonded to tubes with sprayed aluminum deposit are somewhat slower to
respond when tube temperatures are changing rapidly.
The procedure below, which spot welds thermocouple wire to the outer surface of the tube or
header, successfully overcame some difficulties with reliability and durability of welded
thermocouples. Thermocouples installed by this process have lasted for several months,
provided that the wires are routed and supported and protected carefully. They need to be
protected from weather and careless impact damage outside the HRSG.
Thermocouple Installation Process Specification

Thermocouples installed by this process will last for several months if the wires are routed,
supported and protected carefully. They need to be protected from weather and careless impact
damage outside the HRSG. An even more durable method utilizes sheathed thermocouples and
bonds the thermocouple sheath to the header or tube surface in a sprayed aluminum deposit.
Process Specification
Bare two ends of a type K thermocouple for a distance of about 0.5-inch (1.25 cm). Make a 90degree bend half way on each wire in the same direction. Ensure opposite ends are not
connected together (each wire isolated from the other). Do not attach thermocouples to bends, or
within 1-inch (2.5 cm) of a bend or a weld.
Sand all oxide/scale off the thermocouple attachment spot on the tube (approximate 1-inch (2.5
cm) diameter). For T91, preheat local area to 149oC (300F). For T22, preheat to 93oC (200F).
For T11 and carbon steel, preheat 93oC (200F). Using a TAU-107 Hill Technical capacitor
discharge machine, place the magnetic ground clamp within 3-inches (7.6 cm) of the
thermocouple attachment spot (pinch clamp may be used instead, - for pinch clamps, ground
may be further away on header or header attachment). When using a remote ground, over 2-feet
(60 cm) away, increase weld intensity to high (if needed). Set the TAU-107 on automatic and
medium weld intensity (manual may also be used). Grab one wire with the plier welder (or
hemostat long neck plier) and touch the tube with the wire end. The machine will "fire" in about
3 seconds on auto, (or push red button to manually fire). Using a fine piece of emery cloth or
stainless brush, remove any black firing residue from the area where the next wire will attach.
Grab the second wire; note the machine is ready to fire (green light). Pick a spot about 1/8-inch
(0.3 cm) from the first weld and no further than -inch (0.6 cm). Weld the second wire. Brush
residue with stainless wire brush.
Inspect for thermocouple leg distance less than -inch (0.6 cm). Inspect for sound welds, VT
and attempt to slightly wiggle thermocouple attachment. VT inspect for no cracks, use PT to
resolve questions (ANSI Level II or III NDT required). If any unsoundness is noted, remove
(grind) spots and shift location -inch (1.2 cm), repeat steps. Carefully grind and inspect (using
PT or MT) any weld junctions that were not successful to ensure that no cracks are left in place.
This last step is especially important for welds made to T91 tubing.
C-2

Additional Important Installation Requirements

Wrap the bonded ends and adjacent area of tube at each thermocouple pair with insulation
material and secure in place with stainless steel pipe clamps. This protects the wire and spotwelded thermocouple ends and ensures that the thermocouple measure tube or header outer
surface temperature and is not influenced by gas temperature or radiation from other surfaces.
The durability of the thermocouple is most likely threatened by damage to the thermocouple
wires between thermocouple attachment and the recorder. The wires need to be well supported
but retain sufficient allowance for thermal expansions in the HRSG, especially those attached to
the bottom tubes and headers. At any locations where there is any possibility of construction or
operations personnel getting into contact with the wires, they need to be completely enclosed in
conduits or "removeable" covers to prevent inadvertent contact. On the outside of the HRSG
enclosure, the wires also need to be protected from rain, water washing, etc, by threading them
through heavy duty flexible piping to the weather-protected location of the temporary recorders.
Data Recording
It is recommended that the temperature data is recorded, not on strip recorders, but electronically
on CD-ROM using portable recorders. Two recorders are probably required, one on the roof of
the HRSG for the majority of the thermocouples, the other for the thermocouples at the bottom
of the tubes. A high speed scanner can be used; a scan rate of 5 seconds is recommended with
all thermocouples recorded every 5 seconds. Data sets from each event recorded should be
assembled in spreadsheets format to facilitate plotting of selected points and time periods for
preliminary analysis and enables precise temperatures to be extracted for points of special
interest.
Some challenges and solutions associated with thermocouple installation include:
Must prepare for removal of upper baffle plates (need rigging and plan for removal, support
or lowering, and re-installation. This planning needs to be consistent with the scaffolding.
With the upper baffle plates in place it is sometimes not possible to obtain access to the
second tube row since the tube fins and baffle plate block the access. In certain cases access
to the unfinned section of the first row tubing is obstructed.
The scaffolding contractor needs to see the spacings and requirements before the outage if
possible. It is almost always possible to build workable, safe scaffolding in all spaces large
enough for a person to pass through but this may require special scaffolding sizes which
might not be available if the contractor doesnt have good knowledge of what is needed prior
to the outage. A spider climber attached through small upper access door is an alternative to
scaffolding but must be planned ahead of time to be prepared to set up the appropriate upper
support points and rigging.
C-3

Photos of Installation Steps

The primary steps in the thermocouple installation process are shown in Figures C-1 through
C-7.
Figure C-1
Removal of a window of lagging and insulation on an HP downcomer.
C-4

Figure C-2
Removal of surface oxide with gentle grinding.
C-5

Figure C-3
Preheating of cleaned surface and verification of the surface temperature with a Tempil
stick.
C-6

Figure C-4
Attachment of the work lead (attached with a magnet) and the electrode lead
(thermocouple wire held on the surface with a plier) which is electrically connected to the
capacitance discharge power supply.
C-7

Figure C-5
Completed thermocouple junction welds
C-8

Figure C-6
Supporting and guiding the thermocouple wire from the thermocouple junction to the data
acquisition system. It is important that the wire is guided in a manner that provides for
thermal expansion and protection from personnel.
C-9

Figure C-7
Insulation covering the thermocouple junctions on a HPSH tube. The insulation used was
spare manway door insulation that was held in place with two wraps of stainless steel
wire.
C-10

Capacitance Discharge Weld Qualification
Figure C-8
Mock-up T91 tube that was used to qualify the thermocouple junction welding procedure.
Note the two unsuccessful welds above the completed welds. Unsuccessful weld
junctions should be removed by light grinding.
Figure C-9
Polished metallurgical cross-section of one of the mock-up thermocouple junctions.
Although this junction has some minor porosity, undercut and incomplete fusion it will
provide accurate temperature readings and will probably have adequate reliability.
C-11

Figure C-10
Cross-section through another thermocouple junction. This junction has severe porosity
and small cracks (see Figure C-11). This thermocouple junction will provide accurate
temperature readings but is not adequate if longevity and resistance to in-service cracking
are important.
Figure C-11
Close-up of the thermocouple junction shown in Figure C-10. Note the severe porosity,
and cracks that extend toward the tube surface. The tube surface beneath the weld will
have a shallow, but very hard heat affected zone. The combination of porosity,
microcracks, and the hard base metal heat affected zone could lead to cracking.
C-12
D
COST FOR A 96 THERMOCOUPLE MONITORING
SYSTEM
The following is a summary of the approximate costs to procure and install a 96 thermocouple
tube temperature monitoring system. EPRI is continually being asked for these costs, which are
needed for approval process and estimating overall costs. It must be recognized that each unit
and installation is different. So this Appendix is provided purely as an example of the features
which need to be included.
Material
Thermocouple wire.....$6,810.00
20 gage (0.0320-inch/ 0.813 mm diameter) Type K (nickel chromium, nickel aluminum)
thermocouple wire, insulated with solid ceramic fiber and Inconel overbraid for 1200oC
(2200oF) temperature rating, with special limits of error of plus or minus 0.4%) (Type
K20-2-N-350)
Conduit.....$2,000.00
PLC Network.....$33,367.00
This is a data acquisition system included for the 96 thermocouple inputs. This system
was linked with an existing PLC system used for duct burners and chillers. The data
collected by the PLC systems were fed to a server where the information was logged. The
thermocouple PLC system had the capacity to expand to 384 thermocouple inputs. The
estimated cost to add an additional 96 thermocouples is $12,000 (for the extra PLC
thermocouple input modules) plus the additional cost of the thermocouple wire ($6,810)
and extra labor ($7,500 assuming this had been performed when the scaffolding was in
place) leading to a total extra cost of approximately $26,310.
Misc - 5% of Material..............$2,108.85
Labor
Scaffolding..$20,000.00
TC Installation...$7,500.00
PLC Installation (40 mnhrs)..$3,000.00
Total Material + Labor.$74,785.85
D-1
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Heat Recovery Steam Generator (HRSG) Dependability
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Diagnostic/Troubleshooting Monitoring to

Identify Damaging Cycle Chemistry or

Final Report, March 2005

EPRI Project Manager

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Cycle Chemistry Information ....................................................................................A-2

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Deficient chemistry control.

Improper chemical cleaning.

Deficient startup operating practices.

b) Operation with a corrosive environment in flowing feedwater and/or steam-water mixtures,

Reducing feedwater chemistry (single-phase FAC) (i.e., oxidizing-reducing potential,

Entrained water droplets of low pH in steam-water mixture (two-phase FAC).

Excessive waterside deposits (all mechanisms).

Waterside flow disruptions (all mechanisms).

Improper gas side conditions (all mechanisms).

Improper selection/control of evaporator chemical treatments (all mechanisms).

Water treatment plant upsets (CG and HD).

Condenser leaks (HD).

Improper chemical cleaning (HD).

Nonoptimal phosphate treatment such as congruent phosphate treatment (APC).

d) Creation of a corrosive environment during idle periods.

Improper wet layup with stagnant oxygenated water.

Non use of nitrogen blanketing during shutdown.

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Improper chemical cleaning.

Introduction of saturated or subcooled water into the HPSH or RH by over spraying

Delays in establishing natural circulation in successive rows of evaporator tubes during

Circulation of stratified, subcooled liquid in the HP evaporators during startups following

Introduction of cold feedwater into a hot stagnant LP economizer or preheater during

Leakage of cooler feedwater into hotter sections of economizers through passing

Headers are too thick and/or of large diameter.

Introduction of saturated or subcooled water such as undrained condensate or

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Introduction of cold feedwater into the economizer/evaporator headers/drum.

Periodic reverse or stagnant flow of feedwater in the economizer, during startups.

EPRI developed a benchmarking process where an organizations HRSG Dependability Program

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2.1 Introduction to Road Map Steps

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2.2 Step 1: Review of Unit Design, Operational and Maintenance

Demineralized makeup water effluent silica measured once per shift.

Cation conductivity of the feedwater downstream of the ammonia feed.

Cation conductivity of the LP drum saturated steam.

Cation conductivity and sodium of the LP superheat outlet steam.

Cation conductivity of the IP drum saturated steam.

Cation conductivity and sodium of the hot reheat steam.

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The IP and HP evaporator water is showing phosphate and conductivity instabilities

The IP evaporator water has high iron levels.

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