TPW/BPROS/LBCMLM12/eng/PAC/09.12/CH/7729 ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Alstom contributes to the protection of the environment. This leaflet is printed on environmentally-friendly paper.

Able to accurately trendlife consumption andidentify those eventsthat cause the mostdamage to keep plantcompetitive.

Boost plant availability and revenuesHeat Recovery Steam Generators (HRSGs) are required to endure significant cyclic and long term high temperature operation which can, respectively, result in fatigue and creep damage to certain components. While design features are included to maximise the durability of components, actual plant operation can deviate from design assumptions, which may result in higher than expected creep or fatigue damage accumulation. As a part of the ALSPA boiler care package, the AMODIS HRSG life monitoring system aims at providing equipment operators with a means of quantifying the damage accumulation of various operating decisions as related to the overall life expectancy of critical components.

AMODIS HRSGLMHRSG life monitoringHosted by ALSPA Care

POWER AUTOMATION And cONTROls

FUNcTIONAlITYHRSG life monitoring system allows oper-ators to online monitor the accumulation of creep and fatigue damage for critical pressure parts by analysing key tempera-ture, pressure and steam flows from the DCS and performing various calculations to determine temperature profiles and stresses within pressure parts.

The variation of stress with time is ap-propriately monitored by the system so that cycles can be counted to determine fatigue damage and time at temperature can be used to determine creep damage. The system provides various reports and displays to allow operators to monitor the current state of damage and to trend damage accumulation over time, as well as alerting operators to conditions that require immediate attention to avoid

severe damage, thereby allowing an assessment of the effect of operation on the life consumption of key parts.

In addition, with a few strategically placed thermocouples, the system can also monitor: Overspray detection for desuper-heaters Condensate flooding for lower manifoldsThese events can cause severe dam-age in a short period of time and are not readily detectable via normal DCS instrumentation. When the system is installed, it is calibrated with acceptable temperature differentials for the moni-tored components, the system then uses appropriate cycle counting algorithms to detect events that might cause damage to the components.

cUsTOMER BENEFITsAlstoms depth of technical expertise and extensive OEM knowledge represent a unique advantage to provide the tool with accurate life calculations

ReliabilityPermit optimisation of plant operation to minimise component damage through knowledge of the effect of operating practice on damage accumulation rates

Operation optimisationEvaluate component damage so that the effects of, for example, rapid startups can be quanti-fied and used to judge against increased revenue from rapid response to load opportunities

Maintenance optimisationIdentify which components are accumulating damage most rap-idly to aid in setting priorities for the inspections

TPW/BPROS/LBCMLM12/eng/PAC/09.12/CH/7729 ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Alstom contributes to the protection of the environment. This leaflet is printed on environmentally-friendly paper.

For more information please contact Alstom Power.

Visit us online: www.alstom.com

POWER AUTOMATION And cONTROlsAMOdIS HRSGLM

HRSG LIFE MOnItORInG HOStEd by ALSPA CARE

MONITOREd cOMPONENTsThe HRSG components most at risk to failure are those: Subjected to rapid temperature changes and pressure fluctuations during startup and shutdown; subjected to prolonged operation at high temperature and pressure; that are thick-walled and of complex geometry. The key components are usually identified by a design life assessment, or based on experience with similar units. Typical components meeting these criteria are:

COMpOnent nAMe FAtIGue ASSeSSMent CReep ASSeSSMent

HP drum

HPSH outlet manifold

HSPH outlet harp header

RHTR inlet manifold

RHTR outlet manifold

RHTR outlet harp header

In addition to the typical monitoring based on conventional DCS data, the HRSG life monitoring system can identify significant value associated with adding thermocouples to address severe events such as condensate flooding and desuperheater overspray. Such events often go undetected by conventional DCS instrumentation but are sometimes much more damaging than rapid rises in steam temperature during fast starts. The need for such instrumentation is usually identified during design audits an operational data reviews.

HIgHEsT AccURAcYThe real value of the system is its ability to accurately trend life consumption and identify those events that cause the most damage. The actual predictions of creep and fatigue damage are only as accurate as the calibration information provided to the system.

The system is scalable and the absolute accuracy depends on the effort to characterise the initial state of the HRSG. However, even with the system in its most basic form, valuable information is provided about the relative life consumption between hot, warm and cold start-ups.

FlEET APPlIcABIlITYThe HRSG life monitoring system can be installed in any CCPP with HRSG.

sYsTEM cONFIgURATIONThe system is software based and operates on a modern PC platform running MS Windows operating system. The system can interface with most plant historians (e.g. PI) to obtain relevant data, which is stored, processed and results viewed locally on the PC platform.

Most of the algorithms are based on or are consistent with ASTM standards or EN codes; thereby ensuring compliance with most prevailing codes and standards. The system is accredited by TV Rheinland.

Accredited by