MHSEMP ECONOMIZER

TUBES REPLACEMENT

HRSG A/B

MUHAMMAD REHAN KHANMAINTENANCE ENGINEER

EXECUTIVE SUMMARY

• EQUIPMENT OVERVIEW

• REASON FOR TUBE REPLACEMENT

• TUBE REPLACEMENT SCOPE

• TUBE REPLACEMENT STRATEGY

• PRESSURE TESTING STRATEGY

• TIMELINE

3

FGC

GT/ HRSG

STG

IA/ PA

DEMIN II DEMIN I/ WWTU I

RW

CT II

NORTH

SIDE

SOUTH

SIDE

LP EVAPORATOR

MP ECONOMIZER

MP SUPER HEATER

MP EVAPORATOR

WEST SIDE VIEW

BFW INLET

TUBES REPLACEMENT SCOPE

NORTH

SIDE

SOUTH

SIDE

LP EVAPORATOR

MP ECONOMIZER

MP SUPER HEATER

MP EVAPORATOR

WEST SIDE VIEW

TUBES REPLACEMENT STRATEGY

SEPARATOR PLATES

INSULATION

SEPARATOR PLATES

INSULATION

SOUTH SIDE

METHODOLOGY

SOUTH SIDE

METHODOLOGY

CUT 13 TUBES

SOUTH SIDE

PERFORM HYDRO TEST OF THE HEADER

RE-WELD 04 TUBES & PLUG 09 TUBES

METHODOLOGY

PLUG

SOUTH SIDE

PERFORM HYDRO TEST OF THE HEADER

RE-WELD 05 MIDDLE TUBES

PLUG

METHODOLOGY

SOUTH SIDE

PERFORM HYDRO TEST OF THE HEADER

RE-WELD LAST 04 TUBES

METHODOLOGY

PRESSURE TESTING ARRANGEMENT OF HEADER

PRESSURE TESTING STRATEGY

• Current Strategy: Circulation Test of Medium Pressure Side through BFW

Pump

• Problem: Testing time is highPressure holding not possible

• Proposed Strategy:Separate Hydro Testing of the Header

• Only Outlet connections to be cut

• Flange and Nozzle to be welded

• Filling and Pressurization to be done from the bottom nozzle

• Venting to be done from top

• Pressurization will be done through a pneumatic pump

• Pipe will be welded back

Flanges are already installed outside the

equipment

TUBE PLUGGING STRATEGY

NEW TUBE INSERTION STRATEGY

SOUTH SIDE

NORTHSIDE

EAST SIDE VIEW (BFW PUMP SIDE)

Tube will be lifted horizontally with the help of crane

THANK YOU