Helping you prepare for tomorrow

HRSG pressure parts upgrades

HRSG pressure parts replacement

The typical design life of HRSG pressure parts is 25 to 30 years. Operating the HRSG outside of the original specification—and especially cycling gas turbine operation—can result in accelerated lifetime consumption, which typically leads to an increased risk of forced outage and increased Operation & Maintenance costs.

HRSG Attemperators

Attemperators (Desuperheaters) are often a pain point for HRSG users.

  • GE’s HRSG upgrades include the following High Pressure and Reheater attemperator improvements to address your concerns:
  • Redesign of the desuperheater liner system for probe style attemperators
  • Reconfigure HRSG piping to upgrade from a probe style to a ring style attemperator
  • If attemperator drainage is a concern in your older HRSG, GE’s engineers can suggest an upgrade of your drain system (ASME P-HRSG compliant, etc).

HRSG Superheater and Reheater Drain Systems

If your older HRSG is equipped with the “standard” HRSG superheater drain system and you are now considering a shift towards a more cycling operating regime, you may not be completely removing condensate from tubes and lower headers / manifolds during start-up and shut down.

GE’s engineers can suggest an upgrade of your original HRSG front end drain system to increase its capacity. Features of such an upgrade would be:

  • Multiple drain connections from lower headers / manifolds
  • Pipes re-sized for rapid gravity drainage
  • High capacity valves
Helping you improve reliability

HRSG Non-pressure parts upgrades

Tube restraints upgrades

If you’ve upgraded your HRSG, your tube restraint system may be exposed to gas temperatures higher than anticipated at the time your HRSG unit was designed. These higher temperatures can lead to failure of tube restraint components.

To improve reliability of your tube restraint system, GE has developed a range of tube restraint upgrade options that involve a combination of stabilizing and replacing the existing restraint system.

Our HRSG tube restraint system upgrades can be installed during a scheduled major GT outage.

Insulation / liner upgrades

GE’s HRSG upgraded liner / insulation system involves repairing and/or replacing existing materials to improve reliability. The available improvements are based on the latest specifications for new HRSGs, which continue to evolve as we gain more experience with challenging exhaust gas profiles.

Our liner system upgrade can be installed during a scheduled major GT Inspection.

Quick opening access doors

Our Quick Entry Access Doors for HRSGs provide a larger opening that allows personnel to access the boiler more quickly, easily and safely.

Features of the upgraded GE HRSG doors:

  • Hand cranks make it possible to open and close the doors without the use of tools. In addition, a shroud around the hand crank helps avoid unplanned entry to the HRSG.
  • An advanced seal system allows the HRSG liner to expand and contract to keep a constantly tight seal, which minimizes hot spots.
  • The larger GE HRSG door design maintains a skin temperature that meets OSHA requirements.
Helping you detect issues early

Digital solutions

HRSG anomaly detection

GE’s HRSG remote monitoring & diagnostics service uses real-time data to detect anomalies during operation. This service can be offered on any HRSG behind a GE gas turbine.

How it works

  • Operational anomalies are detected by GE’s Monitoring & Diagnostics center
  • Root cause analysis is initiated by GE subject matter experts
  • At completion of root cause analysis, feedback is provided to site


  • Reduce unplanned maintenance costs by early detection of anomalies
  • Enable proactive maintenance of the HRSG

HRSG Life Monitor


HRSGs endure significant cyclic and long-term high temperature operation, resulting in accelerated fatigue and creep damage to critical pressure part components. GE’s HRSG Life Monitor (LM) is an online hardware/software solution that helps quantify lifetime consumption so you can make informed decisions about your critical components’ overall life expectancy and plan major outages and upgrades.

Benefits include:

  • Short/medium-term risk mitigation and operational improvements in the HRSG
  • Long-term lifetime optimization and repair/upgrade planning
  • Support long-term repair and upgrade decision making

Advanced attemperation

Fast, efficient, reliable starts can be an essential factor to a combined-cycle plant’s profitability. Traditional HRSG attemperation control methods are slow to respond to transient conditions, creating potential financial concerns associated with missed dispatch commitments and/or extended operation in unprofitable conditions.

GE’s OpFlex Advanced Attemperator solution uses Model-Based Control (MBC) technology to improve the overall combined cycle start-up and transient loading process. MBC provides better control of the high pressure and reheat interstage attemperators, resulting in reduced upset events, shortened start times, and improved overall dispatch response.

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