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Operation & MaintenanceHRSG PerformanceManagementand ServiceContinuous Condition Assessmentsiemens.com/power-generation-services
Expertise over a widerange of HRSG designsCustomers worldwide have signed Operation and Maintenance (O&M) contracts with Siemens to help maximizetheir plants’ operational performance, reliability and availability by handing over operational tasks and responsibilitiesto Siemens. Experience shows that Heat Recovery SteamGenerators (HRSGs) supported by a service program canactually operate with a higher availability and performance,following the general trend of the electricity producerto maximize the reliability of the entire plant under anAsset Management Program.Siemens’ O&M organization has performed inspections,repairs and upgrades of HRSGs worldwide, winningextensive expertise over a wide range of HRSG designsby different OEMs.Our know-howSiemens’ O&M inspectors have long term experiencein performing: Visual inspections Ultrasonic thickness testing Liquid penetrant testing Hardness testing Borescope inspectionsSiemens recommends regular inspectionsof the HRSG during every minor and majoroutage. Replications metallography Infrared analysis/thermography Root cause analysis Repairs Expertise for cleaning fouled heat transfer surfaces Water chemistrySiemens O&M inspections and repair works are basedupon relevant industry standards and applicable referencesfrom ASME (American Society of Mechanical Engineers)and PED (European Pressure Equipment Directive).2
HRSG Performance Management –Continuous Condition AssessmentThe Siemens’ O&M organization performs Level I andLevel II inspections of HRSGs in order to assess the HRSG’scurrent condition. A systematic maintenance schedulecan help reduce the risk of non-scheduled outages anddecrease the costs for corrective measures.This helps Siemens perform its O&M services costeffectively with optimized reliability. HRSG reliabilitycan be even more important in power markets thatrequire intermittent dispatch mode as opposed to baseload operation, as frequent cycling can decrease thelifetime of HRSG components.Our solutionSiemens developed HRSG Performance Managementto fulfill customer requirements of obtaining the highestavailability and reliability possible.HRSG Performance Management is part of the overall PlantAsset Management Program. It provides regular documentation and analysis of the technical condition and operational performance of the HRSG. These results merge intooperating and servicing recommendations according to theprinciple of reliability centered maintenance optimization.HRSG Performance Management consistsof three major components: Inspection Program Advanced Analytics Fatigue Monitoring SystemTotal ntenanceHighHRSG PMAdvancedAnalyticsMaintenanceHRSG Performance Management (PM) Reliability centered maintenance optimization(Conceptual illustration only. Actual experience may vary)3
Inspection ProgramThe functionThe basis of HRSG Performance Management is theperiodic inspection program for the HRSG which can betailored to the inspection plan and schedule of the powertrain. Thereby, it provides the advantage of a coordinatedoutage of the power train and the HRSG, with a singlepoint of contact. The inspection program consists ofregular Level I and Level II HRSG inspections.The featuresYour benefits can include Consistency in inspection procedure,structure and reporting Recommendations for maintenance andrepair work Recommendations for an adequateinspection and maintenance plan Regular surveillance of HRSG and relatedcomponent conditionThe purpose of the inspection program is to gather information on the condition of the components in order toderive recommendations for immediate action, as well asmedium and long term repair of components. Furthermore,data gathered during each individual inspection is used tohelp identify reliability issues, focus future repair effortsand point out component issues. Additionally, results ofpast inspections can allow Siemens to prioritize those areaswhich require closer attention and non-destructive examination in subsequent inspections. Inspections are managedby experienced Siemens inspectors. Identification of component issues Reduction of forced outage times due toearly detectionLevel I Inspection (Minor Outage)is a visual inspection to detect mechanical andcorrosion issues, performed during a minor inspectionof the gas turbine.Level II Inspections (Major Outage)comprise visual inspection, borescope inspection,metallography and other non-destructive testingaccording to Siemens O&M standards – and ifnecessary, local requirements, and the unit’soperational history.Metallography4
Advanced AnalyticsThe functionOperation and performance monitoring as an integralpart of the HRSG Performance Management allows identification of gradually deteriorating performance and tothe components leading to such deterioration.3D FEM (Finite Elemente Method) Analysis combined withSiemens FMS (Fatique Monitoring System) allows prioritization and customizing of the inspection schedule for thoseareas which require closer attention and non-destructiveexamination in upcoming inspections. This supports longterm planning for replacement of major components.The featuresA comprehensive set of data points, not limited to the HRSGboundaries, are used to record pressure, temperature,water/steam mass flows and heat rejection on the HRSG,HP, IP and LP circuits from the gas turbine exhaust manifoldexpansion joint up to and including the exhaust stack.Daily monitoring of the site data is performed by theSiemens Power Diagnostic Center (PDC). A dedicated dataacquisition team is assigned to verify that data is receivedand processed. Daily monitoring consists of a detailedreview of the previous day’s data for deviations from normal values. Deviations are detected using the proprietaryadvanced rule base tools developed by Power Diagnostics.A comprehensive report shows the processed data invarious graphs. Information derived from the evaluationof the long term trends can allow identification of component issues and recommendations of counter measuresto help avoid unplanned outages.Operations monitoring and trending supports and refinesthe regular inspection work. Advanced Analytics provideonline monitoring of HRSG components as well as plantperformance data within the overall Siemens DigitalServices for power plants.Siemens Digital Services is running on MindSphere, ourrobust operating system that combines new developmentsin data analytics, connectivity and cyber security withproven capabilities for remote maintenance and optimization.The MindSphere ecosystem integrates, manages, analyzesand visualizes data from disparate sources, such as machinedata and weather data, to enable new insights in the cloudor on premise. These insights can enable our experts topredict and prevent failures and uncover opportunitiesfor performance improvements, as well as energy andcost savings.Your benefits can include Readily available dataset to supplyadd-on engineering and services Continuous HRSG monitoring and trending Identification of deviations from design conditions Surveillance and optimization of thermalperformanceMonitoring and Trending: Exemplary identification of HRSG issues5
Fatigue Monitoring SystemThe functionThe featuresSiemens developed Fatigue Monitoring System (FMS)as a module of the Power Diagnostics system.FMS provides calculated values of:FMS calculates the total theoretical material fatigue ofhighly stressed components in the water and steam pipingsystems as the sum of creep fatigue and low-cycle fatigue.Calculation is based on recorded operating conditions ofHRSG components and on available manufacturer data.By computing the residual component lifetime it canprovide an overview of the service life utilization of boilercomponents. Low-cycle fatigue Creep fatigue Total fatigueCreep fatigue is calculated from creep resistance(material property), operating temperature andmembrane stress (or pressure).Low-cycle fatigue is determined by counting the numberof load cycles incurred by a component and comparingthese with the number of cycles to crack initiation.FMS is designed to meet the requirements of thewater-tube boilers and auxiliary installations standard(DIN EN 12952) and has been certified by the technicalinspectorate TÜV Süd.Your benefits can include Monitoring of component condition Transparency in the impact of operating modeon calculated residual life Optimum selection of point in time forrequisite overhaul and inspection Enhanced power plant reliability Detection and prevention of high wearoperating modes C400N2HAD 10CT002 (HD Drum MiWall Temp Top)N2HAD 10CT003N2HAD 10CT004N2HAD 10CT005300Temperature trendsin HP drum at different positions20010000.008N2 HAH21 DZSE (ZSE HP-Header)N2-HAH21 D DWEN2 HAH21 D GE0.006Trend of Creep Fatigue Low-Cycle Fatigue Total Fatigue0.0040.0020.00006–2107–0107–1107–21 07–321 08–1008–20tmin: 2004-06-21 02:00FMS: Exemplary course of monitored data and lifetime consumption608–3009–0909–19t[m-d]
Overall benefits and O&M referencesfor HRSG Performance ManagementOur referencesSiemens O&M inspectors have acquired expertiseover a wide range of HRSG designs and OEMs.This experience comprises the regular inspectionscope during scheduled outages as well as rootcause analyses of component issues and associatedrepairs during unscheduled outages.More than 30 Level II Inspections wereperformed worldwide since 2007 in: UKYour benefitsThe three combined parts of HRSGPerformance Management can provide: Reduction of corrective HRSG service costs France Reduction of preventive HRSG service costsvia maintenance recommendations Spain Morocco More stable HRSG inspection costs overthe life of the program Philippines Optimization of operation, includingavoidance of unfavorable operating conditions Taiwan Singapore Optimization of life cycle of existingplant assetsTotal 15 HRSG‘s in Service Unscheduled services and repairs atestablished rates and facilitated orderingprocess (optional)Severn PowerPont sur SambreKuo KuangToulSanta RitaSan LorenzoSan GabrielArrubalTahaddartPower SerayaWorldwide references encompass a wide range of HRSG OEMs, status: 20177
Published bySiemens AG 2018Power Generation Services DivisionFreyeslebenstrasse 191058 Erlangen, GermanyHRSG ExpertsManfred Wennemann 49 9131 18 6131manfred.wennemann@siemens.comStefan Nendel 49 9131 18 84392stefan.nendel@siemens.comDepartment HeadMartin Mueller 49 9131 18 3294muellermartin@siemens.comArticle No. PSPG-B10278-00-7600Printed in GermanyDispo 34805TH 288-180082 BR 0318X.XCover photo:First Gen Corporation: 1,000 MW Santa Rita Plant HRSG.Photo by Manfred Wennemann.Subject to changes and errors.The information given in this document only containsgeneral descriptions and/or performance features whichmay not always specifically reflect those described, orwhich may undergo modification in the course of furtherdevelopment of the products. The requested performancefeatures are binding only when they are expressly agreedupon in the concluded contract.
principle of reliability centered maintenance optimization. HRSG Performance Management consists of three major components: Inspection Program Advanced Analytics Fatigue
