This case study shows both the need for operators to investigate their plant thoroughly prior to moving to flexible operation and the benefit of working together with specialists who can bring a broader experience and the right mix of skills. This combined monitoring, stress analysis, and operations assessment study has highlighted deficiencies in the design and operation of a large HRSG that will strongly influence its capability to operate in a flexible manner in the future. The work has, in addition, shown that refined stress analysis in terms of FE modelling can be very important in reducing the conservatism inherent in simple inverse design procedures. It has also, however, clearly shown that there are a number of design and operational influences that can be modified so as to allow the strategic option of more flexible operation to be feasible.
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