• No. 11, Jalan Ekoperniagaan 1/29, Taman Ekoperniagaan, 81100 Johor Bahru, Johor Darul Takzim, Malaysia.
  • enquiry@hfsheavy.com
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Power Generation

Power Generation

With more than 50 years of combined experience in managing a wide array of power plant projects, the team in our power generation division is known for delivering impeccable engineering, fabrication, construction, inspection, repair, maintenance and refurbishment services for thermal power plants, co-generation power plants, combined-cycle power plants.

Coupled with our expertly engineered upgrading solutions to lower emissions for all boiler systems and offer greater fuel efficiency, we have the parts and maintenance solutions needed to keep your boiler system operating safely and reliably at its peak condition, whether you are running a Doosan HRSG or a boiler from another manufacturer.

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BOILER INSPECTION

HFS provides inspection resources, technology and software to provide the most thorough and comprehensive boiler inspections unlike any other boiler inspection company. HFS will provide the plant O&M team the ability to PRIORITIZE and MONITOR corrective action, tracking the status of all repair recommendations. HFS will provide detailed reports with analysis and predictive failure information to determine an accurate current and future state of their boiler systems, and repair recommendations to help minimize unscheduled (forced) outages. HFS ensures its clients a thorough and proper inspection is done on every outage, scheduled or unscheduled. And finally, HFS ensures repairs are done correctly with no "short cut" that would jeopardize the boiler integrity.

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SERVICES FEATURES

Basic Inspection Service

Visual inspection of pressure parts, gas path, steel structure and piping. HFS will carry-out evaluation of the results and presenting Inspection report with recommendations.

Additional Options Include

  • Pre-outage walk down and punch list report based on findings and interviews
  • Thermographic survey to review casing and piping and identify leaks or faulty insulation
  • Recommendation for specialist non-destructive examinations (NDE) tasks to be performed during the detailed HRSG inspection (NDE to be performed by a qualified NDE technician)
  • Information Management and Outage planning support

Type of Boilers Include

  • Heat Recovery Steam Generator (HRSG)
  • Horizontal Bottom Support HRSG
  • Horizontal Top Support HRSG
  • Vertical Natural and Forced Circulation
  • Industrial Boiler
  • Coal Fired Conventional Boiler
  • Oil Fired Conventional Boiler
  • Once Through Boiler
  • Oil Heater
  • Tubular Type Heat Exchanger
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GENERAL HRSG INSPECTIONS

A visual survey of the general HRSG condition, external casing, internal gas-side mechanical parts and auxiliary equipment. Readily accessible pressure part components are visually inspected. HISE recommends performing such a general inspection in addition to the basic inspections stipulated by local regulatory requirements.

Time frame requirement: 2 - 3 days HRSG accessibility.

ALIGNING HRSG INSPECTIONS FOR OPTIMIZED AVAILABILITY

In order to prevent forced outages, periodic inspections should be conducted during scheduled outages. This allows the identification of component damage in the earliest stages - when there is still time to schedule a cost-effective repair.

HFS recommends a general inspection every 1 to 2 years and a more detailed inspection every 3 to 5 years. In order to optimize the overall plant availability, it is important to align these inspections with those of the gas turbine. Therefore, the detailed inspection should coincide with a gas turbine planned outage, e.g. the major or hot gas path inspection.

Detailed HRSG Inspections

Includes all the general inspection steps plus a more detailed visual inspection of all accessible pressure parts. This visual inspection will identify any areas of concern that require subsequent non-destructive examination (NDE) to be performed by HFS qualified NDE technician.

Time frame requirement: 4 - 6 days HRSG accessibility.

Pre-Outage

  • Walk down and punch list report based on findings and interviews
  • Thermographic survey to review casing and piping and identify leaks or faulty insulation
  • Recommendation for specialist non-destructive examinations (NDE) tasks to be performed during the detailed HRSG inspection (NDE to be performed by a qualified NDE technician)
  • Outage planning support

During the Outage

  • Supervision of repair or installation works
  • Visual inspection of Desuperheaters, blow down system, deaerator and valves
  • Review of any critical indications from the NDE inspections carried out during the detailed HRSG inspection
  • Documentation and evaluation of the inspection results, using OEM lifetime information management system database for efficient HRSG condition optimization

Post-Outage

  • Walk down to identify start-up problems

BOILER REPAIR

HFS provides a comprehensive selection of boiler repair services.

Our services include: -

  • Retubing - Partial or complete retubing for watertube and firetube boilers.  
  • Welding & fabrication - All welding repairs; boiler shell plate, tubesheets, headers, staybolts, handholes / manholes, faceplates, doors, breechings & supports. Pipe fabrication of steam, water & gas piping to ASME and/or API code, X-Ray quality welding.
  • Appurtenances, Auxiliaries & Fittings - Safety, blowdown, stop & check valves; gauges, test connections, water column piping, feed pumps, cutoffs, preheaters and backflow preventers.
  • Refractory - Firebrick chambers, burner tile, venturi rings, dry oven rings and all refractory repairs.
  • Thermal & Acoustic Insulation - Mineral wool blanket & pipe covers, calcium magnesium silicate (CMS) repairs for interior & exterior of boiler.
  • Mixing Valves - Rebuilding or replacement
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BOILER CLEANING

A clean boiler saves you money, because it burns more efficiently and lasts longer. HFS has always stressed the importance of regular and complete boiler cleaning as part of its clients' ongoing preventive maintenance and fuel-efficiency programs.

Our boiler cleaning services include:

  • Boiler fireside, flue and chimney base cleaning
  • High-powered truck mounted vacuum system
  • Dry-ice (CO2) Blasting - Deep Tube Cleaning
  • Chemical Cleaning of Tube Internal Walls
  • Re-gasketing / re-lining of access doors
  • Repair / Replace door fasteners
  • Sending notification/reminder for scheduled cleanings.

RETROFIT AND UPGRADE CAPABILITIES

Your current boiler system can benefit from a burner retrofit, control upgrade supplemental heat recovery equipment or fuel conversion which can all serve to increase efficiency or reduce emissions.

The retrofitting and upgrading method to be adopted should be decided based on the results of inspection and design review.

HFS can evaluate your current boiler or HRSG unit and recommend the right upgrade or retrofit package for your system.

Some of the retrofits services provided by HFS include: -

  • Engineered improvements, modifications and solutions
  • Heat transfer surface and other pressure part replacement
  • Supply of piping systems, such as attemperators and drains
  • Burner repair and addition
  • Tube leak retrofit
  • Expansion bellow upgrade & retrofit
  • Duct and HRSG casing and liner upgrades
  • Selective Catalytic Reduction (SCR) and CO system addition and replacement
  • Gas & Acoustic baffle modifications
  • Performance efficiency improvements
  • Steam-quality improvements
  • Turnkey demolition and installation services

CONDITION ASSESSMENT SERVICES

To provide a genuine one stop option for all your inspection and assessment needs, HFS also offers basic or advanced NDE/DE techniques to support inspections or follow-on repair works including: -

  • Phased Array
  • Radiography
  • Surface replication
  • Metallurgical tube sample analysis
  • Alloy identification
  • TOFD (Time-Of-Flight-Diffraction) Ultrasonic Testing
  • CHIME Inspection for Corrosion Under Supports
  • Superheater / Reheater Tube Life Prediction (TLP)
  • Remote Inspection with Video Probes, Borescopes and Crawlers
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SPECIALIZED HRSG CONDITION ASSESSMENT

  • Header Inspection - Specialized visual inspection technique to inspect headers for signs of Flow Accelerated Corrosion (FAC)
  • Phased Array Butt Weld Scanner - Specialized device that uses phased array ultrasonics, combined with an encoded circumferential scan, to check the quality of butt welds on manual TIG / orbital pipe welds with diameters from 1.5" to 4.5".
  • Water Chemistry Review / Corrosion Assessment - Corrosion risk assessment based on design, historical chemistry readings, applied chemistry concept and operation profile.
  • Root Cause Analysis - For specific problems
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QUALITY ASSURED BOILER INSPECTION SERVICES

  • Recovery boilers inspections and all components associated with the equipment in the power, industrial and manufacturing industries.
  • Visual boiler inspections, including coal fired boiler and fluidized boiler inspections.
  • Power boilers including fossil fuel for utility and industrial customers. We specialize in BFB and HRSG units.
  • Supplementary firing - Burner inspection, assessment and evaluation
  • Auxiliary equipment
  • Quality Control
  • Code shop inspections
  • Solutions to welding problems including weld monitoring
  • Facility planning and scheduling

DETAIL SERVICES

  • Detail internal and external inspection, including auxiliary equipment
  • Punch-list for critical work items
  • Recommendations for both current and future repairs
  • Required material list to accomplish our recommendations
  • Detailed service report including photographs and electronic copy
  • Detail AutoCAD drawings for report illustrations and mapping
  • Ultrasonic data review and planning
  • NDE review and trending
  • Code material requirement and procurement

Additional Services

  • Quality service and inspection of port cleaning and damper systems.
  • Monthly service contracts specific to customer's requirements and will work with maintenance personnel to ensure proper protective maintenance is met.
  • Turnkey service packages, quarterly or annually, with trained personnel to ensure full potential of the equipment.
  • We offer equipment installation supervision to ensure timely schedules are met along with quality observation for the benefit of client's best interest.
  • Boiler Rebuild Schedules, ASME Code repair verification, waterside inspections, furnace fireside inspections, boiler hanger evaluations, component assessments and component replacement planning.
  • Monitoring NDE data
  • Contractor Cost Reviews
  • Contractor Schedule Reviews

SUPPLY OF SPARE PARTS & REPLACEMENT

Regardless of the ancillary equipment required by your boiler or HRSG system, every part you need is available through the spare parts division of HFS. Each part we offer is engineered and manufactured specifically to suit the original specifications of your equipment.

HFS is dedicated to providing our clients with replacement parts of the highest quality delivered in a timely manner. To benefit our clients, HFS maintains a variety of stock items. These parts are available for immediate delivery, and on very short notice.

Trust us to supply the exact replacement parts you need. You will never go wrong with our professional product knowledge. Not only can we supply OEM replacement parts such as valves, gaskets and tubes, we also provide a wide range of specialty replacement parts and upgrade items.

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Just let us know the parts you require.

  • Fin Tubes
  • Safety Valves
  • Control Valves
  • Gate, Check, Globe, Ball Valves
  • Motor-operated Valves
  • Manway and Handhole Assemblies
  • Demisters and Steam Drum Internals
  • Bundles, Headers, Tubes, Piping / Fittings
  • Instruments, Transmitters, Thermocouples and Thermowells
  • Stack Dampers and Diverter Dampers
  • Level Gauges and Electronic Level Indicators
  • Strainers and Steam Traps
  • Expansion Bellows / Joints
  • Pumps
  • Burners and BMS Systems
  • SCR Systems
  • Environmental Controls & Instrumentation
  • Pre-fabricated Piping

Training

Based on our experience, many users of boiler / HRSG units have never been properly trained. To meet productivity targets and emissions regulations, it is crucial to operate and monitor the essential equipment in the right way every day.

By conducting on-site personnel training seminars which can be tailored for specific site requirements and providing the services of technical personnel to assist our clients' operations teams in unit start-up, we have been able to ensure that all operating procedures are properly and efficiently implemented.

Below are some of the training programs that HFS can provide on-site to suit our clients' schedule:- 

  • Thermal Review of HRSG
  • Codes / Pressure Parts
  • Component Engineering
  • Improvements
  • Life / Age Analysis
  • Damage Mechanisms
  • Water Chemistry
  • Impact of Operation
  • Formulating Strategy
  • Preventive & Reactive Maintenance
  • Inspection Techniques
  • Integrity Tool
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