HRSGs operate in demanding thermal cycling environments behind gas turbines, making certain components susceptible to fatigue, creep, and flow-accelerated corrosion. AQ Process Systems sources and exports the critical spares needed to maintain HRSG reliability, from individual finned tubes to complete module replacements.
We source HRSG-specific components including helically finned tubes (solid, serrated, and segmented fin types), HP/IP/LP headers, duct burner assemblies, SCR and CO catalyst elements, casing expansion joints, and diverter damper parts, all compatible with major HRSG OEMs.
For planned outages, we provide consolidated spare part packages tailored to your HRSG configuration, covering all pressure levels (HP, IP, LP) and auxiliary systems.
| Component | Specification | Description |
|---|---|---|
| Tubes & Bundles | ||
| Finned Tubes (HP/IP/LP) | SA 213 T11/T22/T91, TP304H | Solid/serrated/segmented fins | Helically finned tubes for evaporator, superheater, and economizer sections, all pressure levels. |
| Bare Tubes | SA 213, SA 178 | Various OD and wall thickness | Unfinned tubes for areas where finning is not required or as feedwater preheater replacements. |
| Tube Bundles (Harps) | Pre-fabricated harp assemblies with headers | Complete tube bundle modules (harps), tubes welded to upper and lower headers, ready for installation. |
| Headers & Manifolds | SA 106, SA 335 P11/P22/P91 | Drilled and machined | HP, IP, and LP section headers, inlet, outlet, and intermediate manifolds. |
| Duct Burner Components | ||
| Duct Burner Elements | In-duct line burners | Gas-fired | Replacement duct burner elements (runners/pipes) for supplementary firing in the exhaust duct. |
| Duct Burner Tips & Nozzles | Stainless steel | Drilled-pipe or multi-orifice | Fuel injection tips and flame stabiliser assemblies for duct burner runners. |
| Flame Scanners & Igniters | UV/IR scanners, spark igniters, pilots | Duct burner flame detection, ignition electrodes, and pilot burner assemblies. |
| Emissions Control | ||
| SCR Catalyst Elements | Honeycomb or plate type | V2O5/TiO2 or zeolite | Selective Catalytic Reduction catalyst modules for NOx reduction, replacement or addition layers. |
| CO Catalyst Elements | Precious metal on substrate | Oxidation catalyst | CO oxidation catalyst beds for carbon monoxide and VOC emission compliance. |
| Ammonia Injection Grid (AIG) | SS pipework with injection nozzles | Replacement ammonia injection grids and individual nozzles for SCR reagent distribution. |
| Casing & Structural | ||
| Casing Expansion Joints | Fabric or metallic bellows | Multi-ply | HRSG casing expansion joints accommodating thermal growth between modules and at duct transitions. |
| Diverter Damper Parts | Blades, seals, bearings, actuators | Diverter/bypass damper blade assemblies, seal strips, pivot bearings, and actuator components. |
| Baffles & Flow Guides | SS or alloy steel plate | Custom fabrication | Internal gas flow baffles and turning vanes, preventing gas channelling and improving heat distribution. |
| Tube Support Structures | Alloy steel hangers, guides, anti-vibration bars | Tube supports, anti-vibration bars, and guide structures preventing tube fatigue from gas flow. |
Parts are matched to OEM material specifications and dimensional tolerances. Please provide the equipment manufacturer, model number, and serial number (if available) for precise part identification. Mill Test Certificates (MTC) supplied with all tube materials per EN 10204 3.1.
The most frequently replaced HRSG components include finned tubes (fin erosion and tube leaks), casing expansion joints (fatigue from thermal cycling), duct burner elements (oxidation and warping), SCR catalyst (activity degradation over 3-5 years), diverter damper seals (wear from cycling), and tube support components (creep and oxidation at high temperatures).
We supply solid fin, serrated fin, and segmented fin types in carbon steel, low-alloy (T11, T22, T91), and stainless steel (TP304H, TP347H). Fin material can be carbon steel or stainless steel. All tubes supplied with Mill Test Certificates per EN 10204 3.1.
Yes. We supply pre-fabricated tube bundle assemblies (harps) with tubes welded to upper and lower headers, hydrostatically tested and ready for lift-in installation during an outage.
Yes. We supply replacement SCR catalyst elements (honeycomb and plate type) for NOx reduction, as well as CO oxidation catalyst. Available as full catalyst layer replacements or partial fills to restore performance. Compatible with all major catalyst OEMs.
Our HRSG spares are compatible with units from NEM Energy, Babcock & Wilcox, Doosan, AC Boilers, Aalborg/Alfa Laval, CMI, Nooter Eriksen, and Vogt Power. We match parts to OEM specifications using boiler GA drawings and data sheets.
Share your equipment make, model, and part numbers, we respond within 24 hours.