Technical Support Report

for #1 HRSG of NORTE Ⅱ CCPP

2019. 10.
 이 보고서는 2019년 10월 전력연구원 전문기술센터에서 멕시코 노르테발전소 현장을
방문하여 C급 계획예방정비 기간 중 #1 HRSG의 건전성을 진단하고 2021년 시행될 A
급 예방정비 계획 수립에 필요한 기술적 사항을 검토한 내용을 요약한 것임.

작성자
전력연구원 청정발전연구소 전문기술센터
책임연구원 정 남 근 (서명) 2019. 10
일반연구원 김 현 욱 (서명)
확인자

전력연구원 청정발전연구소 전문기술센터 2019. 10

기계진단기술팀장 박 광 하 (서명)

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Ⅰ. Summary
1. Purpose
The purpose of this inspection is for suggesting the prevention method by
inspecting the internal state of HRSG during O/H

2. Technical support periods and researcher

○ Periods : 2019. 10. 14 ～ 10. 20 (7Days)
○ Persons : Principal researcher Nam-gun jung
Researcher Hyeon-uk kim
3. Specification
○ Type : Horizontal Gas Flow, Top Support, Natural Circulation
○ Size : 18m × 20.5m × 8.4m
○ Evaporation : (HP) 162,400kg/h / (IP) 186,300kg/h / (LP) 17,800kg/h
○ Manufacturer : BHI / 2013.12.19
4. Inspection Contents
○ Review of design characteristics and maintenance history
○ Inspection of facility
○ Diagnosis of operation status
○ Make a report

I
I
I P
H H HHH H HHL H P H E H
Duct P C D C
P H P CP P P P P PP P P P
O
Burne H A P
R R E E E E E E E E P
E
r S T H
SH S HSV V V CCS C V C E C
H C R
H H HAA A OOH O AOO O
2
3 2 1 2 1 1 6 5 4 3 1

Exhaust Gas Flow

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Ⅱ. Review about design, maintenance history
1. Specification
A. Composition of Equipment
○ Two GT to one ST combination Type (GT 143MW×2 + ST 161MW×1 = 447MW)
○ HRSG consists of combustion burner, three-pressure (HP / IP / LP), natural
circulation and horizontal gas stream
○ Support type of HRSG is top support type.
○ LP Drum functions as a water storage and is connected to a water pump and
an integrated deaerator is installed.
B. Tube & Header
Heating OD×Thk Materials Inlet Outlet Fin 1)
Surface (㎜) header header Materials
HRH OD44.5×2.6t SA213 T91 SA335 P22 SA335 P91 A240 TP409
RH
CRH OD44.5×3.0t SA213 T22 SA335 P22 SA335 P22 A240 TP409
HPSH3 OD38.1×4.3t SA213 T91 SA335 P91 SA335 P91 A240 TP409
HPSH2 OD38.1×4.5t SA213 T91 SA335 P22 SA335 P91 A240 TP409
HP HPSH1 OD38.1×3.0t SA213 T22 SA335 P22 SA335 P22 A240 TP409
Eva OD38.1×2.6t SA178-C SA106-C SA106-C C.S.
Eco OD38.1×2.6t SA178-C SA106-C SA106-C C.S.
IPSH OD38.1×2.6t SA178-A SA106-B SA106-B C.S.
IP IP Eva OD38.1×2.6t SA178-A SA106-B SA106-B C.S.
IP Eco OD38.1×2.6t SA178-A SA106-B SA106-B C.S.
LPSH OD38.1×2.6t SA178-A SA106-B SA106-B C.S.
LP DATR OD38.1×2.6t SA178-A SA106-B SA106-B C.S.
CPH OD38.1×2.6t SA178-A SA106-B SA106-B C.S.
1) Fin Type : Serrated, 12% Cr Alloy
2) CPH : Condensate Pre-heater

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2. Performance Data
Gas WTR/STM
Heating
Surface Inlet temp. Outlet temp.
(℃) (℃)
Flow
(t/h)
Inlet press Inlet temp. Outlet temp.
(bar) (℃) (℃)
HRH 584.6 566.4 186.3 21.0 495.9 565.7
RH
CRH 533.3 498.5 186.3 21.6 347.7 496.2
HPSH3 600.6 584.6 162.4 101.1 504.3 567.7
HPSH2 566.4 533.3 162.3 101.7 403.7 507.4
HPSH1 498.5 458.6 162.3 102.3 313.1 403.7
Eva 1∼2 458.6 318.5
Eco 6 314.4 297.6 162.3 103.0 282.6 310.5
HP
Eco 5 297.6 281.5 162.3 103.3 253.2 282.6
Eco 4 278.3 261.7 162.3 103.5 220.8 253.2
Eco 3 227.6 223.1 162.3 103.5 211.8 220.8
Eco 2 223.1 212.6 162.3 103.7 205.8 211.8
Eco 1 212.6 187.0 162.3 104.0 148.2 205.8
IPSH 318.5 314.4 26.2 22.4 219.7 305.1
IP IP Eva 261.7 227.6
IP Eco 223.1 212.6 45.4 47.6 148.2 204.8
LPSH 281.5 278.3 17.8 4.4 148.2 260.4
DATR 187.0 154.6
LP
CPH 2 154.6 137.5 226.1 8.8 119.7 140.4
CPH 1 137.5 89.8 281.4 10.4 60.0 119.7

3. The history of maintenances and failures

○ During commissioning, the burner heats up the surface of tubes located at the
rear, so the burner baffle and perforated plate are installed.

Before improvement Aefore improvement

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4. Operating characteristics
○ As a result of checking the steam turbine power generation in the last month,
it was confirmed that the average power generation was 140MW continuously,
and it was operated at almost the base load state.

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Ⅲ. Inspection Result of Tube in HRSG
1. Module #1
○ Module # 1 is composed of HP SH3, HRH and has the highest gas and vapor
temperature in HRSG.
○ Therefore, this area is the most vulnerable to thermal fatigue crack in header
stub welding due to the largest difference in thermal expansion during startup
and shutdown.
A. Inspection result
(1) Tube condition
○ Location : HP SH3, HRH Tube Panel
○ It is good condition without tube deformation
- This facility has good panel support structure for absorbing thermal expansion, and
the tube is designed with martensite that has a low coefficient of thermal
expansion so it is expected to be able to withstand thermal expansion in the future.
- Norte power plant operates without startup and shutdown. Therefore, if the
same operation pattern is maintained in the future, stable facility operation is
expected.

HTSH3 Tube condition : Good Casing Baffle Plate condition

○ Management Plan
- It is expected that there will be no crack on stub welding zone of the HPSH3
considering tube deformation. If there is any sign such as tube heat dissipation
or surface discoloration it is needed to check on welding zone.
- Cracks in welding can be inspected by visual inspection with penetrant liquid test (PT)
- Several tasks(cut the bumper plate and lift the casing baffle) are required for
weld inspection.

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(2) Casing Baffle Plate
○ Location : Casing baffle in HP SH3
○ Inspection result
- This part is the place where the cracks occurred in central welding part due to
the thermal expansion constraint.
- There is a possibility of bypassing the hot gas between the cracks, so it is
installed in the form of '∧' which is an improvement.
- After the construction in the form of '∧', there is no additional cracks.

Crack condition(2015) Crack after patch welding(2017) Improvement : Good (2019)

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2. Module #2
○ Module # 2 consists of HP SH2, CRH, HP SH, HP Eva 1,2
○ Duct burner is installed in front of the module, so it is necessary to check the
overheat damage caused by combustion and flow characteristics.
(1) Duct Burner
○ Location : Between HRH and HPSH2
○ Inspection result
- In here, there is no scaffolding accessible so detailed inspection was not possible.
- There is no deformation caused by burner heat and perforated plate installed in
front of HP SH2 is also in good condition without deformation or discoloration.

Duct Burner : Good Perforated Plate : Good

(2) Tube condition

○ Location : HP SH2, CRH, HP SH, HP Eva 1,2
○ Inspection result
- Perforated plate is installed in the front of HP SH2 to protect the tube due to
tube overheating.
- Perforated plate in the front of HP SH2 is in good condition without
overheating and discoloration.
- The possibility of tube overheating is not significant under the current
operating conditions.
- There is no damage signs of perforated plate due to fluid-induced vibration

Casing Baffle Plate Tube condition Surface condition

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3. Module #3
○ Module # 3 consists of HP Eva # 1, IP SH, HP Eco # 4 ~ 6 and LP SH Panel.
○ The module has a relatively low combustion gas temperature and is relatively
less concerned with overheating and thermal expansion.
(1) Tube condition
○ Location : HP Eva #1, IP SH, HP Eco #4∼6, LP SH Panel
○ Inspection result : Tubes are good without heat deformation or corrosion.

Tube condition in HP Eva #1 Surface condition in HP Eva #1

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4. Module #4
○ Module # 4 consists of IP Eva, HP Eco #1∼3 and IP Eco Panel.
○ In this module, there is no problems such as overheating and thermal expansion
because of relatively low combustion gas temperature.
○ However, in case of IP Economizer tube, it is necessary to manage the failure
by FAC in the inlet and outlet tube curved because it is operating in the
temperature zone where FAC can occur.
※ For details on FAC, refer to chapter 4 [ FAC Inspection ].
(1) Tube condition
○ Location : IP Eva, HP Eco #1∼3, IP Eco Panel
○ Inspection result : Tubes are good without heat deformation or corrosion.

Tube condition in IP Eva Surface condition in IP Eva

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5. Module #5
○ Module # 5 consists of LP Eva(DATR) and CPH Panel
○ This module does not have a problem with the temperature difference but this
is particularly vulnerable to local erosion (FAC) due to the difference in
velocity of the water-steam mix in evaporation.
○ This part is needed to control low temperature corrosion due to low
combustion gas temperature.
(1) LP Evaporator Tube
○ Inspection result : Tubes are good without heat deformation or corrosion.

Tube condition in LP Eva Surface condition

(2) CPH Panel Tube

○ Inspection result : Tubes are good without heat deformation or corrosion.

Tube condition in CPH Surface condition

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Ⅳ. FAC Inspection
1. Characteristic of FAC
○ FAC causes thickness reduction to pipes, drum wall, tubes designed with
carbon steel or low alloy steel under the certain flow characteristics and
corrosive environment.
○ FAC maximizes the erosion of tubes when the system water temperature is
around 150 ℃ under excessive turbulence or flow rate. therefore, it occurs
frequently in the LP system operating in this temperature range and
sometimes, it occurs in IP Economizer tube.
○ FAC can be confirmed by measuring the concentration of Fe ions dissolved in
the feed water or the thickness of the tube.
○ In the past case, it occurred mainly in the curved pipe part which increases the flow
velocity, but recently, the damage was also confirmed in the straight pipe part of the
upper tube of the LP system [refer to attachment #2]
2. FAC occurrence condition
○ Under turbulent flow or excessive flow rate, water quality conditions affect
the thinning rate as follows.

FAC increases with flow rate Temperature: Most severe near 150 ℃

FAC increases under 20 ppb of High PH reduces FAC(Limit Lev. 10)

Dissolved Oxygen

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3. Inspection result of FAC
○ The possibility of FAC was evaluated by water treatment and water quality
analysis because thickness test was not possible at the vulnerable area.
○ Water quality
Inlet Outlet Fe+ D.O PH Other
temp. temp. (ppb) (ppb)
IP IP ECO 145℃ 200℃ 2-9 9.2-9.6
Riser Pipe 140℃ ※ over 5 9.3-9.4
LP DATR
(EVA) 140℃ ※ - 7 over 5 9.3-9.4 Sample in BFP
※ Estimated value based on 2.7 bar in LP steam pressure at 140 MW steam
turbine output. (Saturation temperature 140℃ at 2.7 bar)
※ AVT water treatment is being applied in LP Drum

(1) IP Economizer
○ Inspection result :
- FAC occurs rarely in IP ECO and as the result of water quality analysis in
IP Drum, it is estimated that there is no FAC progress because the
concentration of Fe ion is low in IP Drum
- Water treatment standard in IP Drum in Norte Power Plant
Specific Cationic conductivity
PH conductivity Silica (ppb) Dissolved
oxygen
PT AVT
9.2 - 9.6 13-47 8-36 <29 <800 2-9

○ Management Plan :
- FAC occurs rarely in IP ECO but it is necessary to check the concentration
of Fe ion in IP Drum periodically.
- If the concentration of Fe ion increases above 20 ppb it is necessary to
check the tube and pipe

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(2) LP system
○ Target Area : LP Drum riser pipe, bended & straight tube of LP Evaporator
○ Inspection result :
- Water quality of LP Drum is being managed based on Feedwater Pump and
the operating condition is about 5 ppb of dissolved oxygen and 7ppb of Fe
ion. so it is good condition
- Water quality of Norte in FWP(LP EVA)
Specific
PH conductivity Cationic Oxygen Iron (ppb) Dissolved
conductivity sequestrant oxygen
9.3 - 9.5 <5 <5 20 <20 <20

○ Management Plan :
- Based on current water quality conditions, the possibility of FAC is low.
- However, the FAC may be generated due to the excessive flow rate in two
phase flow (steam + water)
- Therefore, it is necessary to check the concentration of Fe ions and thickness
of pipe and tube.
(3) Preparation for Class A class O/H
○ Considering the operating conditions of Norte, the thickness test is needed in
IP ECO, LP CPH and DATR for each O/H.
○ In order to do the thickness test, it is necessary to dismantle the insulation.

The location to do thickness Dismantled case of insulation

test in LP Drum Riser Pipe in domestic

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Ⅵ. Summary of inspection result
1. Inspection result of tubes
A. Module #1
○ Considering low thermal deformation rate of tubes, there is no concern about
cracks in the stub welding zone.
B. Module #2
○ During commissioning, the burner heats up the surface of tubes located at the
rear, so the burner baffle and perforated plate are installed.
○ There is no damage and deformation by combustion heat of burner in
surrounding plates and perforated plates
○ Tube of Module # 2 also has no sign of overheating by burner flame
C. Module #3
○ Tubes are good without heat deformation or corrosion.
D. Module #4
○ Tubes are good without heat deformation or corrosion.
E. Module #5
○ Tubes are good without heat deformation or corrosion.

2. Inspection result of FAC

A. IP System
○ IP Economizer is operating at 200℃ of outlet temperature and 2-9 ppb of
dissolved oxygen. so FAC occurs rarely
나. LP System
○ There is no sign of FAC due to the good water quality of LP Drum.
○ Based on current water quality conditions, the possibility of FAC is low.
○ However, the FAC may be generated due to the excessive flow rate in two
phase flow (steam + water)
○ Therefore, it is necessary to check the concentration of Fe ions and thickness
of pipe and tube.

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【 첨부 2】 알카트라나 #2 FAC 손상 분석보고서
1. 분석 배경
○ 본 분석은 ‘19년 2월에 이어 6월 20일 터빈 급전 정지 후 재기동 중 누설상태가 확인
된 #2 HRSG LP Eva Tube의 급속한 내면 감육 원인을 확인하기 위한 것임.
○ ‘19년 2월 손상 튜브에 대해서는 남부발전 기술전문부에서 샘플 튜브를 분석하였음.
분석 결과 해당 튜브는 Flow Accelerated Corrosion(FAC)이 발생하여 누설 손상이
발생된 것으로 평가하였고, 이에 따라 해당 구역 수처리에 사용하는 하이드라진 주입을
중단하여 용존산소 농도를 더 높게 유지하고, pH값을 적정 수준으로 유지할 것을 권
고하였음.
○ 본 분석에서는 LP Eva Tube의 손상기구를 규명하고 유사 튜브에 대한 적절한 관리
대책을 제시하고자 함.

2. 분석 시료
○ 튜브 시료는 아래 그림 1의 표시 부위에서 발췌하였음.

L1-29 R1-27
R1-28

그림 1. 튜브 샘플링 위치
○ 발췌 튜브의 재질은 탄소강이며 상세 규격은 아래 표와 같음.

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 발췌 부위 제원 재질 비고
LP EVA L1-29 OD50.8×2.7t SA178 A 상부에서 0.3m 핀홀 발생
LP EVA R1-27 OD50.8×2.7t SA178 A 손상 없음
LP EVA R1-28 OD50.8×2.7t SA178 A 상부에서 0.8m 핀홀 발생
○ 발췌 튜브의 외관 형태는 그림 2와 같음.

L1-29-P L1-29-D

14㎝

R1-27-B

R1-28-B R1-28-M R1-28-U

그림 2. 시료 튜브 외관 및 내면 상태 평가부위 위치
[첨자 설명 : P(Pinhole), D(Deposit), B(Bottom), M(Middle), U(Upper)]

3. 분석 내용
○ 본 분석에서는 손상 발생 위치와 계통수 온도/압력 등 FAC 관련 요소를 검토하였음.
○ 튜브 내면 표면상태와 감육패턴을 확인하고 FAC 특성을 검토하였음.
○ FAC와 관련된 미세조직 특성을 관찰하고 튜브 감육상태, 과열에 의한 재질변화,
미세조직 및 경도 등을 확인하였음.

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4. 분석 결과
○ 샘플링 튜브의 분석 결과를 요약하면 다음과 같음.
○ 튜브 모재의 재질은 정상적인 178A 탄소강 재질의 특성을 나타냄.
○ 튜브 누설은 내면 감육에 의한 것임.
○ 손상 튜브의 감육손상은 전열튜브 상부 기수혼합물이 지나는 직관부에서 발생함.
○ 감육 부위는 얇고 매끈한 Magnetite 산화피막이 존재하며 유동방향에 따라 Chevron,
Horseshoe, Scallop 등과 같은 감육 형태가 있어, 이들 튜브는 Flow Accelerated
Corrosion(FAC) 또는 Chelate Corrosion(유기산 부식)으로 손상된 형태를 나타냄.
○ 감육표면 조직검사 결과, FAC 발생 부위의 조직학적 특징으로 언급되는 퍼얼라이트
결정립의 선택적 침식 징후는 보이지 않았음.
○ 그 외 당 손상과 관련하여 FAC 취약부로 지목되는 상부 곡관부에서의 감육이 보고
되지 않았으며, 또한 L1-29 튜브에서 감육 발생부 후류측에서 돌연 Deposit 석출이
왕성하게 관찰되었음. 이러한 점은 통상적인 FAC 손상에서는 예상하기 어려운 양상
들을 보여주고 있음.
○ 그러나 HRSG에서 LP EVA 구역은 일반적으로 설계 특성상 FAC에 취약한 것으로
알려져 있고 내면 감육 형태 역시 전형적인 FAC 형태를 나타내고 있어, 금번 튜브
감육 손상의 원인은 FAC에 의한 것으로 판단됨. 단, 이러한 판단의 근거는 해당구역
수질조절을 위해 유기산이 아닌 AVT법을 적용하고 있음을 전제로 한 것임.
○ HRSG LP EVA 튜브 출구 부위는 내부 관수가 이상유동(Two Phase Flow) 형태가
될 것으로 예상되며, 이 경우 FAC를 억제하기 위해 하이드라진 주입중단으로 용존
산소 함량을 증가시켜도 액적속의 산소함량 증가에 한계가 있음.
○ 따라서, HRSG LP EVA FAC 억제를 위한 장기적 방안은 튜브 재질을 Cr 함량이
1.25% 이상인 재질로 변경하여 사용하는 것이 유효할 것으로 판단됨.
○ 각 시료 튜브의 분석 결과는 아래 표와 같음.

발췌 부위 튜브 상태
▪ 튜브 내면 감육은 주로 고온 부위에서 발생
LP EVA ▪ 튜브 내면 감육으로 관벽두께는 1.5㎜까지 감소
L1-29 ▪ 튜브 내면 Chevron 및 Scallop형 내면 감육 발생
▪ 감육부 상단 직후 영역에 돌연 Deposit 부착
▪ 미세조직과 경도는 양호한 상태
LP EVA ▪ 튜브 내면 적색 퇴적물 부착
R1-27 ▪ 퇴적물의 부착량은 많지 않음
▪ 미세조직과 경도는 기준치를 상회하는 양호한 상태
▪ 튜브 내면 감육은 주로 고온 부위에서 발생
LP EVA ▪ 튜브 내면 감육으로 관벽두께는 1.5㎜까지 감소
R1-28 ▪ 튜브 내면 Chevron 및 Scallop형 내면 감육 발생
▪ 미세조직과 경도는 양호한 상태임

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5. 튜브 분석내용
가. LP EVA 특성
○ LP EVA 부위는 아래 Performance Data에 보이는 것과 같이 다른 단상 유동구역
튜브와 달리 상변화에 따른 증발잠열 때문에 튜브 입출구 간의 온도차이가 작음.
따라서 각 튜브 간 열팽창차에 의한 열피로 손상 가능성이 감소하는 반면 각 튜브는
관수 유량과 열흡수량에 따라 기수혼합 비율이 달라지고 튜브 출구측에서 비체적이
달라지면서 개별 튜브의 유속에 큰 차이가 발생할 수 있음.
○ 이러한 이유로 어떤 특정 튜브에서는 심각한 침부식이 발생한 반면, 다른 튜브에서는
침부식 발생이 전혀 없을 수도 있음. 이러한 상황은 특정 튜브에서만 FAC 손상이 발
생한 원인을 설명할 수 있을 것임.
○ 또한, 내부 관수 유량이 부족할 경우 오히려 기수혼합물에서 증기가 차지하는 비중이
높아져 출구부의 전체적 유속은 더 빨라져 FAC를 촉진하고, 후류영역으로 가면서
증기비율이 더 높아지면 FAC 과정에서 용해된 철이온이 석출되면서 Deposit가 부착
될 수 있음. 따라서 HRSG의 운전상태 등에 따른 증기와 관수의 편류도 FAC 발생
위치 결정에 영향을 줄 것으로 판단됨.

[Performance Data]
Gas 측 온도 WTR/STM 측
전열면 입구온도 출구온도 유량 입구압력 입구온도 출구온도
(℃) (℃) (t/h) (kg/㎠) (℃) (℃)
SH 241.0 239.3 30.9 9.4 180.7 216.1
LP EVA 239.3 195.9 241.0 15.4 170.1 180.7
CPH 195.9 124.1 256.7 21.3 59.3 170.1
나. 튜브 내면형상 특성

그림 3. L1-29-D 내면 감육상태 (↑유동방향) 그림 4. L1-29-D 내면 FAC 영역과 Deposit 영역

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그림 5. L1-29-D 내면 Deposit 부착상태 그림 6. R1-27-B 내면 Deposit 색상과 부착상태

그림 7. R1-28-L 내면 Horseshoes 그림 8. R1-28-M 내면 Chevron과 Scallop

그림 9. R1-28-U 내면 Chevron과 Scallop

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