HRSG Pressure Part/Tube Panel Replacement

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October 7 & 8, 2020 at The Chateaux Deer Valley Park City, Utah USA

**** Early registration $1200 before August 7 ****

This seminar is primarily intended for HRSG Owners, Asset Managers, and O&M Management but will be useful for almost anyone working with Combined Cycle or Cogeneration Plants with Heat Recovery Steam Generators. HRSGs have generally high reliability with regard to pressure parts including tubes, piping and headers but inspection, testing and repairs are more difficult and time consuming than in other boilers. In many cases by the time leaks are evident, damage to the tubes, tube panels (HARPS) and tube modules can be widespread.    Repairs can require complete replacement of HARPS and/or entire tube modules.  These require advance planning and procurement to be done successfully in an operational HRSG. Extensive repairs and replacements can also be required due to defects in fabrication, construction and commissioning or from accidents such as gas turbine fires and explosions. Tetra Engineering has supported plant owners, operators and others in these major events for many years.   We have supplied forensics, engineering oversight, due diligence, factory and erection oversight and support for owners in disputes worldwide   This seminar will be presented by experienced instructors in all these areas.


Seminar Syllabus

Introduction and Overview 

  • HRSG Basics (major components, design options, variants)
  • Why Modern HRSG’s Present difficulties for major repairs and replacements
  • Pressure Part Failures in HRSGs and Impact on key reliability and availability metrics

Causes of HRSG Pressure Part Failures 

  • Key Types of Failures
  • Failures from Fabrication Quality issues
  • Failures during Commissioning
  • Failures from operational issues (corrosion, fatigue, overheating and others)
  • Failures from Other Causes.

HRSG Life Management for High Reliability and Availability 

  • Monitoring, Inspection and Useful Remaining Life Assessment
  • Consideration of Operational Changes (Cycling, Low Load, Flexible Operation, Alternate Fuels)

HRSG Pressure Part Repair and Replacement Options

  • Individual Tube Replacement/Plugging/Repair
  • Tube Panel Replacement (Single HARP or Selected HARPS)
  • Tube Module Replacement

Engineering, Procurement, Replacement Actions for HRSG Pressure Parts

  • Specification Development for replacement or upgrade and replace options
  • Re-Engineering Considerations
  • Procurement and Installation Options (Single Source OEM, EPC or Split Contracts)
  • Typical Schedule and Price Issues (local or off-shore sourcing, fabrication options, construction management)
  • Project Supervision and Oversight

HRSG Pressure Part Replacement Case Studies 

  • Extensive Design/Fabrication Quality Issues in New Plant
  • Partial Replacement of Evaporator Tubes
  • Full Replacement of Evaporator Modules
  • Replacement of Tubes Damaged in Turbine Accidents 
  • Partial HARP replacements
  • Issues in Replacement Access

Seminar Leaders

 Mr. David Moelling, PE  - Chief Engineer Tetra Engineering Group, Inc.

 Mr. Andreas Fabricius ,  Senior Consulting Engineer, Tetra Engineering Europe 

 Ms. Early Femiana, PMP,  Manager of Thermal Engineering, Tetra Engineering Group, Inc.

Course Location 

The Chateaux Deer Valley is a luxury resort hotel located in Park City, Utah, a 45 minute drive from Salt Lake City International Airport SLC. 

The Chateaux is located at 7815 Royal Street East, Park City, Utah 84060. Webpage 

A block of Hotel rooms is available at a special rate, please contact Natalie Vasa for Group ID code for special rate. 

Rental Cars and Uber are available at the SLC Airport. 


Early Registration until August 7, 2020 at $1200 USD per person.

The registration fee for the course is $1500 USD per person after the early registration period. 

This fee includes all course materials, breakfast, lunch and coffee breaks each day. 

A Group Dinner is also included on October 7. 

To register or for more information, please contact Natalie Vasa, at our offices in the United States, at +1 (860) 651-4622 ext. 102. or via This email address is being protected from spambots. You need JavaScript enabled to view it.

Managing Boiler & Steam Cycle Pressure Part Integrity

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This training course is primarily intended for experienced O&M staff working in thermal power and process plants, but could also be of interest to corporate engineering and management staff. The objective is to give attendees a comprehensive view of the strategy, actions and considerations involved in effectively managing and thereby assuring the integrity of piping, tubing and vessels that form the pressure boundary to steam or water process fluid. A range of topics relating to the design, inspection and repair of relevant components are treated using a combination of theory and numerous practical examples. The examples are all based on actual project cases encountered by Tetra Engineering staff at plants around the world.

Course Syllabus

Overview of Pressure Part Design and Components

Understand the key considerations involved in designing all the power and process plant components that form the pressure boundary.

  • Review of Design Codes and Standards for Tubes, Piping and Vessels
  • Design Criteria and Design Choices
  • Shop Fabrication and Field Installation Basics

Review of Damage Mechanisms

Gain insight into the theory underlying the most damage mechanisms that affect pressure boundary components, either on the waterside or fire/air-side.

  • General Surface Corrosion and Pitting
  • Flow Accelerated Corrosion and Fluid Erosion
  • Underdeposit Attack
  • Fatigue and Corrosion Fatigue
  • Creep and Creep Fatigue
  • Fire or Gas Side Erosion or Attack
  • Other Mechanisms (Hydrogren Embrittlement, Stress-Corrosion Cracking etc.)

Inspection and Surveillance

A survey of the inspection and surveillance techniques and practices that are available and how to best choose the best approach for assuring pressure part integrity over time while considering the impact of economic and operational constraints.

  • Setting the Strategy
  • Overview of Practical NDE Techniques
  • Field Inspection Practice
    • Covered Piping Systems
    • Boiler Tubes, Headers and Internal Interconnect Piping
    • Pressure Vessels and Tanks
  • How to Review Operating Data
  • Inspection Data Knowledge Management

Life Assessments 

Learn about various methods to predict wear and damage in pressure parts

  • Component Life Assessment Techniques
  • Overview of “Fitness-for-Service” Assessments
  • Combining Analysis and Inspection to Improve Condition Assessments

Root Cause Analysis (RCA)

Methods or approaches for determining the root cause are presented in summary fashion. Whatever the method chosen, it is important to remember that the ultimate objective is to find a solution that prevents further failures.

  • Collecting Evidence and Identifying Failure Mechnaism
  • A Summary of Root Cause Analysis Methods

Welding & Repair of Pressure Parts

Learn about how to best plan and then perform repairs to meet the challenge of achieving schedule, cost and quality objectives.

  • Assessing Repair Options and Planning Repairs
  • Review of Available Welding & Repair Codes and Guidelines (ASME XI, PCC-2 etc.)
  • Assessing and Assuring Welding Quality
  • Special Materials (P91)
  • Tracking Repair History

Sample Case Histories and Discussion

Examples from recent projects performed by Tetra staff are presented, covering field inspections, life assessments and failure analyses on a variety of steam cycle pressure part components.

This course is offered in a 2 day format and a condensed 1 day format.

For  more information about this course please contact Christine Vallon, or call our European office at +33 4 92 96 92 54. Tetra offers courses on client site or as per our public course schedule

PipeVue 2.0

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PipeVue 2.0 Demo from Tetra Engineering on Vimeo.

For more information about our Piping Services contact Peter Jackson This email address is being protected from spambots. You need JavaScript enabled to view it. (Americas) or Andreas Fabricius This email address is being protected from spambots. You need JavaScript enabled to view it. (EMEA). 


About Us

Established in 1988, Tetra Engineering has more than 25 years experience providing solutions to the power industry. We specialize in solutions for HRSGs, conventional boilers & steam-cycle balance of plant.


Our Locations

Offices in: Connecticut, USA; Nice, France; Dubai, UAE.