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Bremco, Inc.

Bill Kitterman

10/22/2014 Bremco Inc, Canadian HRSG Forum 1


Tube Leaks
Panel Replacements

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Stick thru with J bevel
Socket Set
Side Stick thru
Set on
Spot face set on
Extruded header

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What section of unit ?
Upper, Lower, or elsewhere
Tube to header weld
Header location (in a bundle or open)

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Raise, Lower Panel (Harps)
Jack panels apart
Cut your way in weld your way out
Plugging

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Cutting jumper piping, drains, etc
Restraints
Stress Reliving (if necessary)
Rigging

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Cutting restraints
Cutting Drains
Blocking

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Tube leak location:
Tube 12 counting east from the HRSG
center.
Gas Flow 4 feet (approx.) east of HRSG centerline.

Very
narrow Big wide
access access lane.
lane,
5 wide
20-24
approx.
wide.

HPSH2 RH2 HPSH3 HPSH4 HPEvap HPEvap

Downcomer Manifold

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Amount of tubes needed to be cut out
Tube stock availability

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In our eyes least desirable method
Strong Code involvement
P/T 91 Should involve engineered solutions because
of ASME Section 1 requirements
Highest skill level needed
Strong potential for stress reliving in 2 areas
(Upper and lower headers)
Possible circulation / flow concerns

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Header to Header
Involves window in Header sections
plugging individual tubes on both upper and
lower headers and replacing removed
section of header, usually used when tubes
are not readily accessed
Tube to Tube / Header ( Gas Flow)
Involves plugging tube stub, or direct to
header on both the upper and lower header.
Requires access to tube/header in gas path .
The preferred method for this repair should
be a dutchman or a pup which would
allow the tube to remain in the circuit
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Job Traveler
Item Data Report ( P3,P4,P6,U1A Forms etc.)
Weld Procedure and Supporting PQR
Welder Qualifications with supporting
Continuity Log.
Material Receiving Report
Mapping and/or Photo Documentation.
Required NDE Documentation
R-1, R-2 Form, Certificate of Compliance

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P -1
When weld metal exceeds .750(1.9cm) or base metal exceeds 1(2.54cm).
P -4 ( 1.250 Chrome) P/T/F-11
For post weld heat treat one of three conditions must be met
Base metal at weld exceeds .625(1.59cm) in thickness
Maximum specified carbon content exceeds .15%
Base metals greater than or equal to .625(1.59cm) are not preheated to 250 F
(121C)
P 5A (2.250 Chrome) P/T/F-22
For post weld heat treat one of the four conditions must be met
Maximum specified chrome content exceeds 3%
Base metal thickness exceeds .625(1.59cm) at the weld
Maximum carbon content exceeds .15%
Preheat of 300 F (149 C) is not used

P 15E ( 9 Chrome) P/T/F-91


Stress reliving required for all applications

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Trials and Tribulations
Understanding TRUE
down times
New material to old

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Relatively new material and applications has
caused adjustments in weld/repair procedures
Preheat and interpass temperature must be
between 400 and 600 F. (204.5 315.5 C)
Thermocouple design and placement is critical
to success of weld
New material to old material creates
additional challenges

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Weld out is usually the shortest process
Wrap and thermocouple placement must occur
before preheat can begin
Preheat to get to proper temperature before welding
can begin including soak time necessary
Welding occurs
Potential for rewrap/ Hydrogen bakeout procedure
Post weld heat treat can start usually lasting
anywhere from 12-14 hours
Small bore valves ( could really extend time)

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Magnetism
Not an uncommon occurrence weldors will see
puddle jumping from side to side as they lay a
bead in
May require material to be degassed
Hardness of material
Old vs New

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Complete Modules
Requires largest space requirements, also requires
largest cranes (500T +) (453MT) based on module
size and location of crane placement
Panel Replacements
Typically requires smaller crane (125T )(113MT) as
panel size is up to 50,000 lbs (22.68 KG)
Build in Place
Utilized when crane is either impractical or space
considerations just dont allow.

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Most Challenging based on skill
sets needed
Requires smaller crane

Takes up less plant footprint

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Planning
Scope Identification
Identifying areas of concern
Material lead time
Outage duration
Coordination issues
Laydown areas
Resources
Cranes/Lulls/Forktrucks etc
Facilities, Utilities

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Turnkey or Multivendor
Turnkey one contact one voice but typically higher
priced
Innovative solutions
Multivendor
Coordination issues and supply delivery concerns
(multiple voices)
Possibly less communication between vendors

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Time to plan next years outage is while you
are in this one. Delivery on panels etc.
historically run 18-26 weeks but we have seen
lead time as long as 48-52 weeks depending on
material grade etc.

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Questions

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