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Drum Weld Critical Crack Size Pre-Outage Assessment and Application Experience

Tuesday, December 1, 2020 @ 2:00pm EST/11:00am PST

Presentation Synopsis

HP Steam Drums are becoming a common inspection finding in HRSGs that experience more frequent starts. These findings often result in expensive and time-consuming repairs. ASME FFS/API-579 code provides the ability to perform a Fitness for Service (FFS) calculation to determine whether a steam drum can return to service with a crack in place. As per the code, the steam drum can return to service if the crack has not reached its critical size.

HRST has helped a few of its clients with a pre-outage assessment that can help determine the critical crack size for each of the nozzles of an HP Steam Drum. The calculations can help determine what crack sizes (a combination of crack length and depth) are acceptable and what the next steps are when one is identified. Case studies from HRST’s experience with critical crack size assessments and subsequent drum weld inspection will also be showcased as part of this discussion.

Key Takeaways for Users

  • Drum weld cracks may not necessarily warrant repairs depending on the crack sizes
  • Critical crack calculations can be performed prior to outages
  • For cracks below the critical size limit, recommendations will be provided for when the next inspection or repair is required
  • Having an active program for drum weld inspection and maintenance can help reduce the risk of unforeseen and expensive repairs during outages.


Anand-Gopa-KumarAnand, HRST’s Analysis Department

Anand joined the HRST team in June 2013. He leads HRST’s Analysis Department. Anand is experienced in several types of analyses including Flow Accelerated Corrosion (FAC) Risk Assessments, HRSG Performance Assessments, Combustion Turbine Upgrade Assessments, Computational Fluid Dynamics (CFD) Simulation, Finite Element Analysis (FEA), Root Cause Failure Analysis (RCFA), Fitness for Service and Remaining Life Assessments, High Energy Piping, HRSG Cycling Assessments, and Statistical Analysis.


HRST Regional Representatives
(You can also email to have us connect you with the right person)

Northwest – Ned Congdon |
Direct: 925-434-5510 | Mobile: 925-984-6835

Southwest – David Heyn |
Direct: 424-427-5510 | Mobile: 562-688-9930

North-Central – Behnam Kholghi |
Direct: 952-767-8155 | Cell: 404-444-3319

Northeast – Craig Dube |
Direct: 207-731-8310 | Mobile: 207-478-8865

Mid-Atlantic – Madeline Fink |
Direct: 443-776-8710 | Mobile: 443-852-2051

Southeast – Bryan Craig |
Direct: 813-848-0110 | Mobile: 612-743-1009

Gulf Coast — Alan Martin |
Direct: 409-444-3410 | Mobile: 409-920-1799

Rest of the World
SE Asia – Huy Nguyen |
Direct: +84 2822 538 841 | Mobile: +84 888 572 089

Australia & New Zealand — Lester Stanley |
Direct: 952-767-8131 | Mobile: 952-210-3607

Mexico – Cesar Moreno |
Direct: 424-427-5511 | Mobile: 619-214-1869

South America — Bryan Craig |
Direct: 813-848-0110 | Mobile: 612-743-1009 |

All Other Regions — Brent Cosgrove |
Direct: 952-767-8128 | Mobile: 612-414-1442

About HRST

HRST, Inc. provides power plant boiler technical service and products. We specialize in Heat Recovery Steam Generators (HRSGs) and Waste Heat Boilers. Our engineers, technicians, and designers pride themselves on performing quality inspections, detailed analysis projects, developing engineered design upgrades, serving as Technical Advisors to plants, and offering professional HRSG training courses to help our clients avoid and solve boiler problems. Since 1998, HRST has specialized in technical services and product designs for heat recovery steam generators (HRSGs), waste heat boilers, and smaller gas/oil-fired power boilers globally.

Products and Services


* HRSG Inspections
* Borescope Inspection
* Commissioning & Warranty Inspection
* Firing Duct Drone Inspection
* Online Inspection
* Remote Inspection


* Computational Fluid Dynamics (CFD) Analysis
* Covered Piping Systems (CPS)
* Deposit Weight Density Analysis
* Finite Element Analysis (FEA)
* Flow Accelerated Corrosion (FAC) Risk Assessment
* Gas Turbine Upgrade Thermal Analysis
* HRSG Cycling Assessment
* Layup Guidance
* Performance Evaluation
* Root Cause Failure Analysis


* Gas Flow Components
* Gas Side Tube Cleaning
* HRSG Access Doors
* HRST QuenchMaster
* Air Attemperation System
* HRST ShockMaster
* Economizer
* Liner & Insulation Retrofit Upgrades
* Pipe Penetration Seal (High Temperature Fabric
* Pressure Parts

HRSG Training

* HRSG Academy
* On-Demand Training (Virtual Classroom)



EDEN PRAIRIE, Minnesota 55344
United States

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