Planning ahead

HRSG maintenance, repairs and replacements

When it comes to HRSG component failures, there are many warning signs you can look for—from tube water leaks or casing hot spots. With the right information at hand, you can contact GE for maintenance and repairs before they become a major problem.

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Did you know?

  • The most common contributing factors to HRSG waterside failures (tubes, modules, steam drum internals) are water steam cycle chemistry and gas turbine cyclic operation.
  • Drain valve leakages, control valve malfunction, desuperheater liner cracks, tube restraint supports and duct liner failures are among the most common mechanical failures on HRSGs.
  • Items that are important but generally overlooked are drum water level controls, stack expansion joints, piping supports and proper valve maintenance.

If your HRSG is exhibiting performance issues in any of these areas, it’s time to get in touch with your GE maintenance and repair specialists!

Your questions, answered

Learn more about our HRSG inspection services

What is the benefit of performing regular inspections?

  • HRSG inspections help ensure reliable operation over the next planned operating period. 
  • If implemented early enough, GE recommendations for improved operation or maintenance practices can limit premature life consumption.
  • A visual HRSG inspection is typically performed on an annual basis to identify repair scope for the upcoming major outage. A detailed inspection of the HRSG is usually performed in parallel to a major GT outage, which typically occurs every 4-5 years. 

Who performs HRSG inspections?

Our team of GE field engineers has extensive experience with HRSG inspection and troubleshooting.

Why come to GE for HRSG inspections?

  • GE considers your “total plant” when developing HRSG solutions.​
  • Our team of experts has extensive experience not only with legacy Alstom and Doosan HRSGs, but also with oOEM units.
  • GE’s inspectors have  access to a community of engineering experts throughout the global GE organization.

When are HRSG inspections performed?

Inspection outages are aligned with GT inspection​ outages. 

Inspections

Explore our inspections

Scope of annual inspection

The annual visual inspection includes a survey of the inlet duct, boiler casing, gas path, upper & lower vestibules, piping & boiler pressure parts, HRSG stack, duct burners, SCR & CO catalyst, blowdown tank, and drums. The standard scope can be customized to your needs.

Scope of minor inspection

The major inspection comprises the scope of a minor inspection and additional inspection of specific components. GE will use the OEM recommendations in addition to GE’s standards to determine the scope of a more detailed inspection for specific components such as attemperators, emissions control equipment, duct burners, control valves, and safety valves. The standard scope can be customized to your needs.

Scope of major inspection

A major inspection includes a scope of minor inspection and an additional inspection of specific components. GE will use OEM recommendations plus GE standards to determine the scope of a more detailed inspection for specific components such as attemperators, emissions control equipment, duct burners, control valves, and safety valves. The scope can be standard or customized to your needs.

Additional inspections

The following inspections can be performed as stand-alone services or can be added to any HRSG inspection.

  • Operating behavior analysis
  • Pre-shutdown walkdown
  • Restart walkdown
  • Water chemistry analysis
Pressure parts services

Analysis of HRSG pressure parts and performance testing at GE’s Metallurgical Lab

HRSG failure analysis

GE’s experts will assist you in determining the metallurgical root causes of tube failure and recommend corrective actions.

Remaining life assessment

For steam tubing, GE’s experts can provide an estimate of the remaining serviceable life based on proprietary lifetime calculation models.

Serviceability Assessment

For water tubing, GE’s experts can provide an estimate of the remaining serviceable life based on proprietary lifetime calculation models.

Internal deposit weight and compositions analysis

This analysis is typically performed for water tubing. The report will include tabular results and a brief discussion of the findings.

Serviceability assessment for dissimilar metal weld (DMW)

GE’s experts will assess the serviceability of the DMW using information obtained from the lab examination.

Replacement parts

My HRSG needs replacement parts, including drum gaskets and drain valves. Can GE help?

YES. As an HRSG OEM with a global supply chain network, GE can provide in-kind parts for your HRSG.

Further reading

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