HRSG & Steam Boilers

We specialize in comprehensive servicing of heat recovery steam generators (HRSG) and conventional steam boilers. Our work focuses on ensuring the reliability, safety, and optimal efficiency of energy installations. We offer a wide range of services—from regular inspections to advanced technical consulting—supporting clients in maintaining operational continuity and minimizing operating costs.
Our strength lies in an experienced team of engineers specializing in materials science, thermal engineering, process engineering, and energy equipment. We combine advanced theoretical knowledge with practical experience gained at industrial facilities worldwide. This enables us to effectively handle tasks requiring precise technical analysis, such as inspections, operational optimization, and failure cause investigations. Our services are tailored to each installation’s specifics, allowing efficient risk management and extending the lifespan of critical components.

Key Services Related to HRSG and Steam Boilers:
HRSG and Steam Boiler Inspections

Detailed offline and in-service inspections on the flue gas, steam, and water sides. Beyond identifying issues, we determine their causes and provide further recommendations and actions to prevent recurrence. Each inspection concludes with a detailed report highlighting critical findings. During inspections, we also perform water-side borescopic (RVI) checks, conducting tests to precisely assess internal component conditions, detecting corrosion, erosion, or deposits.

Remote Inspection Support

An effective solution for international clients requiring technical support while minimizing costs tied to expert travel or operating in locations where safety prevents physical presence. Using modern technologies like real-time video transmission, operational data analysis, and online consultations, we conduct detailed technical assessments, support diagnostics, and recommend necessary actions. This approach ensures rapid response and downtime minimization without additional logistical resources.

Energy Pipeline Inspections

Regular inspections of energy pipelines, hangers, and spring supports are vital for reliable operation. Over time, installations degrade, so early damage detection prevents major failures that could lead to costly downtime and losses.

NDT Oversight and Metallurgical Analysis

Hosseg oversees NDT testing, coordinating execution teams during regular shutdowns and inspections. This includes testing pressure components of HRSG and steam boilers. While some damage is visually detectable, others require non-destructive testing (NDT) methods, especially for issues like:

• Material fatigue damage
• Structural degradation from prolonged stress
• Corrosion-induced cracks
• Surface wear from intense media flow

To avoid conducting NDT in incorrect locations, we provide professional process oversight. Effective NDT requires precisely selecting areas most prone to degradation, considering installation design and operating conditions. Through thorough preparation and detailed analysis of operational and historical data, we accurately identify potential risk zones during operation. Additionally, we supervise NDT teams to optimize shutdown and repair periods. Hosseg also leverages advanced analytical tools, such as material testing and metallurgical analysis, to maximize inspection efficiency. We offer end-to-end support—from shutdown planning and on-site supervision to post-testing result analysis.

We assess suitability and operational capability for continued use, identifying risks tied to potentially suspect HRSG and steam boiler components. This enables optimal lifecycle management and continuous condition monitoring, ensuring comprehensive insight into failure-free operation of both equipment and the entire facility.

Root Cause Failure Analysis

Every inspection is backed by detailed analyses, including Root Cause Analysis (RCA) for identified HRSG or steam boiler damage—a process identifying failure root causes. This involves pinpointing defect origins and developing and implementing effective preventive solutions. Root Cause Failure Analysis (RCFA) deeply investigates defect formation mechanisms, enabling precise preventive actions. Collaborating with research institutions and accessing cutting-edge materials labs, we accurately assess damage scope and conduct detailed causal studies at the molecular level. This approach ensures a comprehensive technical condition evaluation and supports long-term installation reliability.

Water Chemistry

When needed, we assess boiler water chemistry for a complete HRSG or steam boiler analysis. Proper water chemistry in power plants is critical for maintaining HRSG pipe integrity and preventing corrosion. Feedwater must be adequately purified of contaminants, gases, and organic substances, with parameters like pH and conductivity tightly controlled. Contaminants can evaporate into steam and deposit on turbines, causing damage. Water chemistry is regulated using ammonia, amines, and oxygen scavengers like hydrazine. Boiling processes in HRSG concentrate contaminants, potentially causing corrosion and pipe failures. Thus, various treatment methods—like phosphating, AVT, or oxygen treatment—are used, often combining multiple approaches in one system.

FAC

Hosseg analyzes and monitors flow-accelerated corrosion (FAC), a primary cause of pipe failures in HRSG heat exchangers. FAC gradually thins pipe walls, leading to cracks and leaks, especially in low-pressure evaporator sections. Factors include temperature, water chemistry, and fluid flow velocity. Optimizing chemical parameters, like raising pH and creating an oxidizing environment, can reduce FAC risk, though sometimes replacing pipes with more resistant alloys is necessary. Mechanical erosion also occurs in areas like pipe bends, where high-velocity two-phase flow damages protective layers. Hosseg offers FAC risk assessments and long-term ultrasonic monitoring programs for early threat detection and inspection plan optimization, minimizing costs and failure risks.