Boiler & HRSG Offline Inspections

The offline (or cold) inspection is an essential O&M activity at any thermal power or process plant. For steam generating equipment, whether it's a small industrial package boiler or a large utility-scale supercritical coal boiler, this is especially critical since only during a shutdown can the condition of all internal components be assessed in detail.

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Boiler & HRSG Offline Inspections

The high costs associated with forced outages required that plants engage in any effort to anticipate problems in steam and power generation components that are susceptible to service-related damage. Inspection is therefore an essential O&M activity to determine the present condition of any power plant equipment.  Offline inspections during outages are mandated at regular intervals in accordance with the requirements of local regulatory bodies and insurers.  The required scope of these inspections is often limited.  Damage mechanisms vary in severity depending on the design layout and materials selected by the boiler/HRSG OEM, the plant operating regime and the units age and operating history.  

Tetra Engineering has performed thousands of field inspections on an extremely broad range of thermal steam generation plants, from small fire tube boilers to the latest large triple-pressure with reheat HRSG units.  The fundamental basis for any effective offline inspection is the visual inspection, which means that the inspector(s) must be highly experienced.  Nearly anyone can point out an obviously broken fixture, what’s important is to look for the more subtle damage and to link the damage with suspected mechanisms and root causes.  Therefore, it’s essential that to ensure inspection quality for any boiler or HRSG is that the inspector understands the process and the potential associated damage phenomena in detail.  This is where Tetra Engineering’s extensive Root Cause Analysis (RCA) work experience is critical, our inspectors don’t just do field inspections, they are also regular and essential contributors and participants in our desktop RCA and Remaining Life Analysis (RLA) studies.

In addition to the impact of their fundamental design differences, today’s boilers and HRSGs are subject to a wider range of duty in power applications.  Whereas baseload operation was once normal for utility-scale steam generators and in particular HRSGs, today’s electric power market dictates that units operate in cycling duty.  This has resulted in many units experiencing damage much earlier in life, particularly older HRSG units that were designed with baseload operation in mind.  Newer boilers and particularly HRSG designs require components to operate at higher pressures and higher temperatures while still achieving the requisite flexibility to meet today’s market demands.   The result is greater risk of certain types of damage such as creep as well as fatigue and corrosion fatigue from increased thermal stresses due rapid starts.

Boiler & HRSG Offline Inspections
Boiler & HRSG Offline Inspections
Boiler & HRSG Offline Inspections

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To discuss how we might assist you to improve your plant's performance or to maintain its value over time

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Related HRSG & Boiler Inspections Services

In-Service Inspection

In-Service Inspection

The in-service boiler or HRSG inspection has the advantage of being able to be conducted at nearly any time. It encompasses the external components of and typically refers to a unit that is running (or "hot"), but can also encompass a unit that is ready to run and in standby.

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Boiler & HRSG Offline Inspections

Boiler & HRSG Offline Inspections

The offline (or cold) inspection is an essential O&M activity at any thermal power or process plant. For steam generating equipment, whether it's a small industrial package boiler or a large utility-scale supercritical coal boiler, this is especially critical since only during a shutdown can the condition of all internal components be assessed in detail.

learn more
Borescope Inspection

Borescope Inspection

The borescope is an essential tool for inspecting of power plant components. Commonly used in high-value rotating power-plant equipment such as steam turbines, gas turbines and generators it is also extremely useful for checking the internal or to reach external surfaces of boiler and HRSG tubes and piping.

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Remote/Offsite Inspection Support

Remote/Offsite Inspection Support

In the case where travel time or logistics prevent a Tetra inspector from being present on site, inspections can be conducted remotely in collaboration with client staff

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Tuning of Control and Monitoring Systems

Tuning of Control and Monitoring Systems

Improving or rectifying the operation of process control and monitoring systems in a thermal power plant is an important activity. This can entail both in-service and outage activities, and is an important corollary to an effective inspection program.

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Welding Repair/Refurbishment Supervision

Welding Repair/Refurbishment Supervision

The quality of the thousands of factory and field welds present in the pressure part modules of a thermal power plant is critical for assuring long-term reliable operation.

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Inspection Planning & Supervision

Inspection Planning & Supervision

Tetra can provide experts to assist your staff in planning upcoming outages, as well as provide on-site supervision and surveillance to assure work quality and schedule.

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Drone Inspection

Drone Inspection

As part of the Tetra Engineering inspection services, we offer remote visual assessments of your boiler/HRSGs using quadcopter drone technology

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Tetra Engineering Group Achieves NBIC ‘R’ Stamp Certification
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Tetra Engineering Group Achieves NBIC ‘R’ Stamp Certification

Tetra Engineering Group, Inc. has been granted an “R” Stamp for Design for Alterations by the National Board of Boiler and Pressure Vessel Inspectors (NBIC).

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