September 2017 Technology Newsletter

Please click on the image below to access the latest edition (September 2017) of ETD's Technology Newsletter. This describes various power and process plant activities, new technologies and methodologies developed for plant inspection, integrity and life assessment, material quality checks, issues with P91 & P92 Steels, new industry (third party and Group Sponsored) projects and other initiatives such as ETD’s plant services for inspection and life assessment.

Special acknowledgement must go to page 9, which provides information on ETD’s various forthcoming Training Courses and Conferences during 2017. Particular mention must be made of our upcoming 2-day Conference on Fabrication and Use of P91 Steel: International Industry & Plant Experience. (preceded by a 2-day Training Course on P91-P92 Issues) which will be held in Australia next month.

Recent Completed Project on 'Root Cause Failure Analysis Study of Methanol Reformer Pigtails' for an Asian Petrochemical Plant

An Asian petrochemical plant requested ETD to provide a quotation to perform testing, Root Cause Failure Analysis (RCA) and Life assessment Study, initially for two methanol reformer pigtail parts that have been removed from service. It was then proposed to examine a further four pigtail samples (two that have been removed from service, and two as-new samples).

The scope of the work included:

  • Visual and dimensional examination of the (2 off) pigtail samples including internal and external appearance;
  • Assessment of condition of the internal and external surface including identification of inclusions/ contaminations, welding defects etc (if any exists);
  • Chemical analysis of weld material to determine the chemical composition of the pigtail weld filler material to establish actual material constituents and the level of aluminium & titanium;
  • Metallographic examination of the pigtail samples using optical microscopy to assess the condition of internal and external surfaces, to identify phase changes in microstructure / material degradation/ precipitations and also to identify the damage mechanism(s);
  • Hardness testing and evaluation to determine the equivalent tensile strength values (using published hardness/ UTS correlation tables) to assess the mechanical strength or softening of the pigtail materials or welds;
  • Basic review of design drawings, design & operating parameters, previous failure and maintenance history.
  • Detailing condition assessment and/or RCA based on the findings of above investigations to determine whether there are any damages/ cracks and the root cause(s) of the damage.
  • Remaining life assessment of the pigtail components based on the findings of above detailed investigations.
  • Examination of these specimens using Scanning Electron Microscope (SEM) to assess the presence and volume of gamma-prime phase and perform detailed analysis of microstructure.
  • Performing Post Weld Heat Treatment (PWHT) on the welded joint of the pigtail samples;
  • Comparing of the results, to determine the effect of in-service aging on the component.
  • Compiling a report covering results of all above investigations, condition & life assessment, root cause analysis & recommendations for any further actions to be taken for safe operation of the pigtail components which are in service.

ETD has established expertise in the failure analysis. For more information about our failure analysis services please click here.

 

Recent Completed Project on 'Failure Analysis of Submerged Chain Conveyor' for a Middle Eastern Power Plant

ETD is pleased to announce the successful recent completion of a failure analysis project. A Middle Eastern power plant invited ETD to submit a proposal to carry out failure analysis of 3 (three) links chain samples removed from the failed/ damaged areas. The work involves performing chain failure analysis study including root cause analysis of damage mechanism(s) based on laboratory testing and assessment on the removed chain samples.

The work carried out included:

  • Firstly, visual and dimensional examination was performed in order to assess any obvious issues with the quality of surface appearance of the samples, corrosion damage, past repairs and any other signs of distress etc and to select representative locations for more detailed investigation such as locations of the exact failed areas or where the presence of any defects/ corrosion has been detected.
  • Secondly, metallographic examination was completed on sections through the wall of the chain samples using optical microscopy. This enabled the condition of surfaces to be assessed and the damage mechanism(s) to be identified. The microstructure was then examined for evidence of degradation and to identify the damage mechanism(s).
  • Next, hardness testing and evaluation was performed on the chain material to assess the mechanical condition of the material. The measured hardness values were converted to equivalent tensile strength values (using published hardness/UTS correlation tables, ASME standards etc) to assess the mechanical strength or softening of the chain materials.
  • Then, chemical analysis of the base material concluded to determine the chemical composition of the chain material to establish actual material constituents which will be compared against standard design specification.
  • Once we had the results from above, Root Cause Failure analysis (RCA) was carried out based on the detailed information gathered on respective components.
  • Lastly, a report was issued detailing the findings with photographic records including test results, images, detail explanation of root causes and highlighting any possible causes for concern and the chain integrity. The report also included recommendations for possible remedial actions that may prevent re-occurrence of failures and improve component integrity.

For more information about our failure analysis services please click here.

Recent Completed Project on 'On-Site Inspection and Remaining Life Assessment of a Boiler' for a European Power Plant

ETD is pleased to announce the successful recent completion of a remaining life assessment project.

A European based power plant approached ETD to submit a proposal on Remaining Life Assessment (RLA) of one of their boilers. The work involved performing on-site inspections - ultrasonic thickness measurements (UT) of tubes (wall thickness & bore oxide scale), replication, hardness measurements of selected components from FSOH and ROH. The inspection data was then used to estimate tube metal temperature and identify material degradation which could then be used for damage assessment and predicting the remaining life of outlet headers and tubes of final superheater & reheater.

The scope of the work included:

  1. Reviewing the drawings of FSOH & ROH, tube banks of the boiler to be studied and identify accessible test locations for on-site inspections;
  2. Performing on-site ultrasonic thickness (UT) measurements of tube wall thickness and bore oxide scale considering ~40% of total tubes for FSOH & for ROH;
  3. Performing on-site replication and hardness measurements on straight tubes, T-piece nozzle weldments, stub tube weldments and hot reheat pipe weldment for FSOH & ROH;
  4. Assessment of all replicas by using OM (optical microscope) and to confirm the damage condition, further assessment of selected P/T/F91 & T23 replicas by using SEM (Scanning Electron Microscope) and if necessary, to confirm the damage condition, further assessment of selected P/T/F91 replicas by using ETD’s SFM (Scanning Force Microscope) at ETD lab;
  5. Assessment of damage and material degradation of outlet headers, tubes, T-piece nozzle weldments, stub tube weldments and hot reheat pipe weldments for FSOH & ROH based on the replication and hardness measurements data;
  6. Review & interpretation of UT inspection data and estimation of wall thickness loss & tube metal temperature;
  7. Assessment of the remaining life of FSOH & ROH components based on estimated tube metal temperature and other inspection data;
  8. Review & analysis of previous failures, inspection and maintenance data for other pressure parts of the boiler to complete the life assessment study;
  9. Preparing a full report including results of on-site inspections, analysis results of damage & life assessment study and make recommendations for any further actions to be taken for safe and reliable operation of the boiler.

 For more information on our remaining life assessment services, please click here.

Recent Completed Project on 'Failure Analysis of Economiser Tubes' for a Middle Eastern Power Plant

Following recent findings of a leakage ETD were approached to carry out root cause failure analysis on an economiser tube removed from a coal-fired power plant in the Middle East.

ETD Consulting (ETD) has been involved in a number of consultancy projects and is internationally considered to be an industry expert in matters concerning power plant materials, operation, maintenance, inspection and life assessment, failure analysis, particularly for issues related to carbon steel, low alloy steel & P91/ T91 steel components. ETD has been involved in a number of failure analyses including root cause analysis of damage mechanism, inspection and consultancy projects concerning carbon & all alloy steels for power plants worldwide.  

The objectives and scope of the work to be carried out was:

  • Visual and dimensional examination of the tube sample including internal deposit, appearance and condition of tube surfaces;
  • Macroscopic analysis to assess the physical appearance of tube/weld joint;
  • Metallographic examination of the tube sample using optical microscopy to assess the condition of internal and external surfaces, weld joint, material degradation and also to identify the damage mechanism(s);
  • Further assessment of selected tube area by using SEM (Scanning Electron Microscope) to confirm the damage mechanism(s), if necessary;
  • Hardness testing and evaluation to determine the equivalent tensile strength values (using published hardness/UTS correlation tables) to assess the mechanical strength or softening of the tube materials or welds;
  • Chemical analysis of base material to determine the chemical composition of the tube material to establish actual material constituents;
  • Chemical analysis of internal oxide/ deposits to determine the presence of impurities and constituents that may lead to the failure (depends on the oxide thickness), if necessary;
  • Basic review of design drawings, operating parameters, previous failure and maintenance history;
  • Root Cause Failure Analysis (RCA) based on the findings of above investigations to determine the actual causes of damage mechanism(s);
  • Report covering results of investigations, failure analysis, detail explanation of root causes & recommendations for any further actions to be taken to prevent reoccurrence of failures and for safe operation of the component.

ETD has established expertise in the failure analysis. For more information about our failure analysis services please click here.

Recent Completed Project on 'Creep Assessment Using SFM & Standard Replication' for a European Plant

ETD is pleased to announce the successful recent completion of a Creep Assessment project. The principal objective of this study was to examine components in order to detect the presence of any creep cavities. The components are manufactured in P11 steel. In order to perform this study ETD suggested using standard replication technique and its most advanced equipment Scanning Force Microscope (SFM) and (EDSE).

The scope of the work included:

  • Firstly, operation details such as temperature, pressure and service hours were checked in advance in order to have a general understanding of the condition of the components. Component drawings were then checked to organize inspection with the SFM and to identify replica spots and EDSE sampling locations.
  • Secondly, Component inspection was performed with the SFM microscope. The number of scans depended on the number of areas identified for inspection on each component. Replication was then performed after SFM scanning is completed. The replication was carried out at the same location where SFM scan was carried out. The number of replicas depended on the number of areas identified for examination and time available at the plant.
  • Next, The EDSE was used to cut out two to three specimens (depending on the accessibility of the location) of the dimensions. These were studied later in the laboratory to counter check the damage detected by the SFM and replication. For such a comparison it will be necessary to study these samples both under the Optical and Scanning Electron Microscopes.
  • Lastly, a report was submitted covering results of investigations and recommendations for any further actions to be taken.

For more information on our On-Site Services, please click here.

Recent Completed Project on 'Root Cause Failure Analysis of a Push Plate Sub Sample' for an Asian Power Plant

ETD is pleased to announce the successful recent completion of a failure analysis project.

An Asian based client approached ETD to provide a quotation to perform Root Cause Failure Analysis (RCA) of a push plate sub sample.

The scope of the work carried out was:

  • Visual examination of the sample including component appearance, evidence of corrosion and/or other surface defects;
  • Assessment of condition of the surfaces;
  • Dimensional examination of the sample to examine the thickness;
  • Chemical analysis of base material to determine the chemical composition of the sample material to establish actual material constituents;
  • Metallographic examination of the sample using optical microscopy to assess the condition of surfaces, material degradation and also to identify the damage mechanism(s);
  • Further assessment using Scanning Electron Microscope (SEM) to confirm the damage mechanism;
  • Hardness testing and evaluation to determine the equivalent tensile strength values (using published hardness/UTS correlation tables) to assess the mechanical strength or softening of the sample materials or welds;
  • Basic review of design drawings, operating parameters, previous failure and maintenance history.
  • Root Cause Failure Analysis (RCA) based on the findings of above investigations.
  • Report covering results of investigations, RCA and recommendations for any further actions to be taken for safe operation of the components.

For more information on our Failure Analysis services please click here.

Launch of a new Group Sponsored Project - "Crack Assessment in Turbines": ETD's 'CRACKFIT' Procedure and Software for Pressure Vessels - Now Being Expanded to Include Cracks in Turbines

ETD Proposal No: 1576-tp-prop17

To read the Technical Proposal Outline please click on the Proposal Image.

ETD has launched a new proposal for a Group Sponsored Project. The proposal is entitled ‘CRACKFIT – Defect Assessment Tool for Boilers/Pressure Vessels & Turbines’. 

Crackfit© is the ETD’s commercial procedure and software for assessing cracks in pressure vessels, piping and standard fracture mechanics specimens, both at low and high temperature. It is based on the prototype initially developed with the support of the European Commission and European industry. The commercial version was developed by ETD as a joint venture in collaboration with the European industry and independently verified by experts. Crackfit carries out crack and life assessment both deterministically and probabilistically - probably the most advanced procedure for probabilistic crack assessment. Crackfit significantly reduces the time required to carry out assessment, in some cases from weeks to days!  Crackfit comes with an optional crack initiation and growth database for base metal, HAZ and welds and for many materials of interest to industry.  It deals with defects such as lack of fusion / penetration in welds (defects at weld toes), internal and external surface emerging or embedded defects in straight pipes and pipe bends, defects at stress concentrations such as sharp corners (T-pieces, nozzles), defects in plates etc.

The software is user friendly for industry engineers who would like to carry out defect assessments without having to go through the different established codes or country / in-house defect assessment practices. Procedures including BS7910, the French code RCC-MR A16 and the European procedure ‘HIDA’ are available as software options. The software allows for failure analysis (fast fracture, plastic collapse and ligament rupture) and the evaluation of damage mechanisms such as creep, fatigue, and creep-fatigue interaction.

If you would like to obtain the full proposal or would like to discuss this Group Sponsored Project in more detail, please don't hesitate to contact us

Offer of On-Site Plant Services, Root Cause Failure Analysis and Life Assessment

If you have an upcoming outage in 2017 or beyond, ETD Consulting - a UK based company operating globally, would like to offer a quote for your outage work. We can make technically excellent and cost-effective proposals for your on-site NDE services and/ or post-outage life assessment.

The advantage of ETD over many others is that ETD can conduct both on-site services and post-outage life assessment. We are also independent so can provide you impartial services. Our expertise in plant integrity/ life assessment, Condition Assessment, FFS, RBI etc. is well established and is backed up by state-of-the-art technologies developed in collaboration with the international industry – technologies that are the envy of our competitors. Our long established expertise means that, when we review your plant’s historical operations and maintenance data, we know what to look for and what needs to be inspected and tested during the outage. We can therefore direct and co-ordinate our testing and inspection teams to undertake the most appropriate tests in the right spots, ensuring the most productive use of your outage time, to gather the most useful testing data and samples for analysis. We can then, if required, analyse the data and samples and provide you with life assessment reporting and forward thinking operations and maintenance recommendations, or even develop maintenance plans for you, as you require.
 
Whether your need is for one-off replication services, other NDE on-site services and/or life assessment - or if you want one organisation to design, manage and run your entire outage and life assessment process, ETD can assist.

We know that many organisations require supplier pre-approval and we are happy to undertake such registrations if needed.

If you would be interested in discussing potential projects further please feel free to contact us.