HRSG Fundamentals and Refresher
HRSG role in combined-cycle power plants
HRSG types (single-pressure, multi-pressure, once-through, drum-type)
Major components:
Economizers, evaporators, superheaters, reheaters
Drums, headers, tube banks, ductwork
Design limitations and operating envelopes
Normal operating modes and load variations
Safety systems and protection philosophy
Maintenance Practices and Degradation Mechanisms
HRSG inspection methods and intervals
Common degradation mechanisms:
Flow-accelerated corrosion (FAC)
Under-deposit corrosion
Thermal fatigue and creep
Tube vibration and wear
Drum internals and separator maintenance
Expansion joints, liners, and duct burners inspection
Water and steam chemistry control and its impact on HRSG life
Maintenance planning and outage preparation
Troubleshooting and Performance Improvement
Systematic troubleshooting methodology
Common HRSG operational problems:
Tube leaks and failures
High differential pressure
Abnormal drum levels
Poor steam temperature control
Duct burner instability
Alarm analysis and root cause identification
Case studies and lessons learned
Operational best practices to minimize thermal stress
Reliability improvement and life extension strategies
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