Introduction:

The Heat Recovery Steam Generator (HRSG) is a critical component in combined cycle power plants, capturing exhaust heat from gas turbines to generate steam and improve overall plant efficiency. This training program is designed by Global Horizon Training and Consulting Center to provide a deep technical understanding of HRSG systems, design, operation, performance optimization, and maintenance. The course is tailored for engineers, technical staff, and professionals working in the power generation sector, especially within combined cycle environments.

Objectives:

By the end of this program, participants will be able to:

• Understand the working principles and configurations of HRSG systems.

• Identify the key components and their functions within an HRSG.

• Analyze HRSG performance parameters and efficiency improvement strategies.

• Apply best practices in HRSG inspection, troubleshooting, and maintenance.

• Recognize and mitigate common operational and safety challenges.

Course Methodology:

• Technical presentations and diagrams

• Real-world case studies and problem-solving exercises

• Group discussions and technical Q&A sessions

• Maintenance simulation scenarios

• Review of OEM best practices and operational checklists

Organizational Impact:

• Enhanced reliability and performance of HRSG systems

• Reduction in unplanned shutdowns and maintenance costs

• Improved safety and regulatory compliance

• Stronger technical competencies within plant operations teams

Target Audience:

• Mechanical, Electrical, and Instrumentation Engineers

• Maintenance and Reliability Engineers

• Power Plant Operators and Technicians

• Engineering Managers and Technical Supervisors

• Professionals involved in combined cycle power plant operations

Outlines:

Day 1:

Fundamentals of Heat Recovery Steam Generators

• Overview of Combined Cycle Power Plants

• HRSG role in energy efficiency and sustainability

• HRSG types and configurations (horizontal vs vertical)

• Basic thermodynamic principles and heat transfer processes

Day 2:

HRSG Components and Functional Overview

• High-pressure, intermediate-pressure, and low-pressure sections

• Superheaters, reheaters, economizers, and evaporators

• Duct burners and supplementary firing

• Drums, valves, piping, and bypass systems

Day 3:

Design Considerations and Performance Analysis

• HRSG design parameters and sizing

• Pinch and approach points

• Steam temperature control and attemperation

• Efficiency calculation and performance evaluation

Day 4:

HRSG Operation, Control, and Safety

• Startup, shutdown, and load-following procedures

• Water chemistry and steam purity management

• Monitoring instrumentation and DCS integration

• Common faults and alarm management

• Safety procedures and incident prevention

Day 5:

Maintenance, Troubleshooting, and Case Studies

• Tube failure analysis and preventive measures

• Fouling, corrosion, and stress-related damages

• Inspection intervals and NDT techniques

• Maintenance scheduling and best practices

• Real-life case studies from operational plants