Offer of Unique P91, P92 Services for New & Running Plants

In this P91/P92 Services Brochure you will find useful and interesting information on ETD’s unique P91, P92 Services for New & Running Plants. These include:

a) Inspection, Monitoring, Assessment & Life Extension Services: Over the last decade through its collaborative research programmes, with its international industry partners, involving large pipe testing ETD has developed a suite of specialist inspection and monitoring techniques and life assessment methodologies that it offers to plants worldwide. These are offered in addition to the conventional NDE techniques for the detection and sizing of defects, together with replication and portable hardness testing for component condition and remaining life assessment. ETD carries out code-based calculations of creep life using either deterministic or probabilistic (another of ETD specialities) methodologies. Examples of these techniques include: Scanning Force Microscope (SFM) for early stage damage detection, Miniature sample removal (boat sampling) for quality checks and life/condition assessment, Precision Portable Hardness Tester (known as ‘Smart sleeve’), Obikou for Pipe Strengthening and Life Extension and Defect/Crack Assessment.

 b) Root Cause Failure Analysis: Over the years ETD has developed an expertise in the root cause failure investigation of P91 and P92 components/welds. In the recent past, ETD has investigated a range of failures of T91 tube components and welds, and cracking in P91 pipes and drain-line components in conventional boilers and HRSGs. In these investigations, ETD identifies the root cause of the damage, and proposes remedial actions and solutions to the problem.

c) Consultancy & Guidelines on Materials & Welding: ETD provides P91 and P92 users with advice and guidance on the metallurgy, welding and heat treatment of these steels. This service includes reviewing weld procedure specifications (WPS) for similar and dissimilar metal welds, inspection of NDE records, and guidelines for repair welding of P91. The advice is provided to both the plant operators and designers/ manufacturers. This advice is based on ETD’s P91 experience in a number of Group Sponsored Projects including its running of the International P91 Users Group (Int. P91UG) for international industry over more than a decade and its involvement as consultants to many a power plants worldwide.

For further details of our P91/P92 services and opportunities being offered, please click on the image above.

Offer of Both Traditional and Innovative Plant ‘Inspection’ & ‘Life Assessment’ Services

In this Plant Services Brochure you will find useful and interesting information on ETD’s plant inspection and integrity/ life assessment services. These include:

a) Traditional NDE inspection: Using, for example, Boroscopy, PAUT (Phased Array Ultrasonic Testing), EMAT (Electromagnetic Acoustic Testing), PEC (Pulsed Eddy Current), LFET (Low Frequency Electromagnetic Testing), Replication (including replica assessment), Hardness testing, Wall Thickness profiling, Oxide Thickness measurement etc.

b) New state-of-the-art Innovative NDE Inspection Techniques: Developed through ETD’s collaborative joint industry projects. This includes equipment such as (details later in this brochure): a) Portable spark erosion ‘boat sampling’ machine (called EDSE), b) Portable Scanning Force Microscope (SFM) for on-site early stage nano and micro level damage detection especially in materials like P91, c) ‘Obikou’ pipe reinforcement technique which offers creep life extension of creep damaged seamless or seam welded pipes, by simply and quickly reinforcing them with multiple layers of a thin high-temperature alloy strip, and, d) Our newly invented first of its kind portable ‘precision’ hardness tester, called ‘Smart Sleeve’, which improves the accuracy of the ‘MIC 10’ or other portable hardness testers.

c) Integrity/ Life Assessment: In addition to inspection, ETD offers independent and impartial plant safe remaining life assessment using both deterministic and probabilistic techniques. It has its own software for crack assessment, RBM/ RBI and carries out routinely both root cause failure analysis (RCA), replica and life extension/ assessment for pressure parts and turbine components and RCM.

Details of the services and opportunities being offered can be seen by clicking on the image.

Renting of Electrical Discharge Sampling Equipment to a client for a project in the Middle East

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ETD was approached by a European based company to rent their Electrical Discharge Sampling Equipment (EDSE) for a month to cut samples from a power plant in the Middle East.

The EDSE was developed by ETD in collaboration with international partners to aid in the condition and life assessment of components. The sampling of in-service components has long been seen as an effective way of determining actual material properties and sub-surface material condition. However, many of the existing methods of sample removal require mechanical cutting which can deform the surface and usually require weld repair. Unlike the traditional mechanical ‘boat sampler’, with EDSE, the surface damage if any is of the level of only a few microns. EDSE can also be used to cut out specimens for small punch testing and miniature creep, fatigue or tensile testing for more accurate quantitative life assessment.

The EDSE is available to rent or for purchase. For more information on our EDSE services, please click here.

Recently Completed Electrical Discharge Sampling Equipment (EDSE) Project in Europe

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A European based company approached ETD to submit a proposal on cutting samples of very small thickness (1mm or less) from pieces of a ring segment and a combustor basket. The work on the ring segment and combustor basket supplied to ETD by the client was carried out at the ETD site by one of our engineers. One sample was cut from the ring segment and one from the combustor basket. This is to understand the interface between the coating and the substrate. Before cutting out the specimen from the combustor basket the area around the piece to be cut out was cleaned of the ceramic coating and then a thin piece cut out by our EDSE. Photos and videos were made of the cutting process and all samples sent back to the client.

The EDSE was developed by ETD in collaboration with international partners to aid in the condition and life assessment of components. The sampling of in-service components has long been seen as an effective way of determining actual material properties and sub-surface material condition. However, many of the existing methods of sample removal require mechanical cutting which can deform the surface and usually require weld repair. Unlike the traditional mechanical ‘boat sampler’, with EDSE, the surface damage if any is of the level of only a few microns. EDSE can also be used to cut out specimens for small punch testing and miniature creep, fatigue or tensile testing for more accurate quantitative life assessment.

For more information on our EDSE 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.

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.

Recent Sale of an EDSE

ETD is pleased to announce the successful recent sale of one of our Electrical Discharge Sampling Equipment (EDSE). This is a unique tool for NDT sample cutting, developed together with one of our international partners.

EDSE is one of a groundbreaking range of NDT and engineering consultancy services offered by ETD. It cuts out small slices between 1 to 20 mm thick and approximately 20mm square or 40mm square or 40mm x 120mm from thick section components for their remaining life evaluation and extension. The unique cutting process leaves behind cavities with round edges that do not require repair.

The cutting time for a standard specimen is about 1.5 hours and the EDSE can be used on horizontal, vertical and angled surfaces by either strapping to the component or through the use of a magnetic mount. It has been used both on pressure vessels and turbine rotors but can also be used on any industrial structures such as windmills, bridges etc.

The purchase came from a Czech Republic based company. They focus on improving in service reliability and service life of power engineering devices – material tests, residual service life assessment, etc.

The EDSE is available for purchase or rental or for use as part of ETD’s services.

For more information on the Electrical Discharge Sampling Equipment click here.

EDSE NDT Project Recently Completed

ETD are pleased to announce the successful recent completion of an NDT project using our Electrical Discharge Sampling Equipment (EDSE).

EDSE is a unique tool for NDT sample cutting, developed through R&D work involving ETD and one of our international partners. Its spark erosion cutting technique leaves behind no stress concentrations and rounded edges that do not require repair. EDSE is one of a groundbreaking range of NDT and engineering consultancy services offered by ETD. 

In the most recent project, the EDSE was used successfully to remove two axial samples from the interstage gland area of a Steam Turbine (ST) rotor, where 2 off ‘boat samples’ were taken on the LP rotor between the stage 3 and 4 rotor discs. ETD mounted the EDSE cutting head in the confined space between the rotor discs using a magnetic mounting system and bespoke frame. The rotor itself was from a double-flow Low Pressure (LP) type ST with 5 stages.  

The boat samples taken both measured 12mm in depth (thickness), 20mm width and were approx. 80mm in length. The material of interest was removed, since it contained small surface defects which had been detected by NDT – in need of root cause analysis to pin point the cause of material degradation.  

EDSE cutting samples on-site for this project

Following this work, the rotor is to be machined in order to dress-out and remove the excavation sites (by diametric reduction of the interstage gland area) as part of the component refurbishment cycle, before the expected return to service of the rotor.

The EDSE is available for purchase or rental, or for use as part of ETD’s services .

For more information  on the Electrical Discharge Sampling Equipment click here.

ETD's SFM and EDSE technologies feature in Combined Cycle Journal

ETD Consulting's Scanning Force Microscope (SFM) and Electronic Discharge Sampling Equipment (EDSE) are considered in the Combined Cycle Journal in an article titled 'New NDE tools facilitate in-service evaluation of P91 condition'

The article, from January 2014, highlights the benefits of SFM and EDSE  as compared to older technologies

ETD Consulting has developed SFM and EDSE as part of its R&D work with international partners. The technologies are available, either for sale or for use as part of our on-site services. Thus, if you engage ETD Consulting for your inspection and analysis needs, you can be sure that you will benefit from the most advanced detection and sampling technologies in the field. 


To read the Combined Cycle Journal article please click here.

To read more about these products please click here.

For enquiries please contact us.