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.

Recent Completed Project on ‘Accelerated Rupture Testing and Integrity/Life Assessment of HP Steam Header Material’

In a recent outage in a process plant in the Middle East, damages (i.e. misalignment, bulging, graphitisation etc.) were observed on certain welds of HP steam header. The scope of study involved metallographic examination, including microstructure analysis and hardness testing, and accelerated rupture testing for material samples removed from respective sections. This allowed assessment of the remaining life of the service-exposed header material, enabling improved remaining life predictions for the components within the HP steam header system.

HP Steam Header.jpg

For more information about our life assessment services please click here.

On-site Inspection and Remaining Life Assessment for Boiler Pressure Parts for an Asian Power Plant

NDE_on_pipe.png

The client contacted ETD to submit a proposal on Remaining Life Assessment (RLA) for boiler pressure parts by performing on-site inspection, analysis and assessment on tubes, T-piece nozzles, stub tube weldments and hot reheat pipe weldment for final superheater (FSOH) & reheater (ROH). The work involved performing on-site inspections - ultrasonic thickness measurements (UT) of tubes (wall thickness & bore oxide scale), EMAT (Electromagnetic Acoustic Transducer), replication and hardness measurements of selected locations. The inspection data was then used to estimate effective tube metal temperature and identify material degradation which could be used for damage assessment and predicting the remaining life of outlet headers and tubes of the FSOH & ROH.

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

  • Reviewing the drawings of FSOH & ROH, tube banks of the boiler to be studied and identify accessible test locations for on-site inspections;
  • Performing on-site ultrasonic thickness (UT) measurements of tube wall thickness and bore oxide scale for FSOH & for ROH tubes;
  • Performing on-site EMAT (Electromagnetic Acoustic Transducer) testing of tube wall thickness for FSOH & ROH tubes;
  • 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;
  • Assessing all replicas by using OM (optical microscope) to confirm the damage condition. Further assessment was also made of selected P/T/F91 & T23 replica(s) by using SEM (Scanning Electron Microscope), if necessary, to confirm the damage condition;
  • Assessing the damage and material degradation of FSOH & ROH outlet headers, tubes, T-piece nozzle weldments, stub tube weldments and hot reheat pipe weldments based on the replication and hardness measurements data;
  • Reviewing & analysing UT inspection data and estimation of wall thickness loss & tube metal temperature;
  • Assessing the remaining life of FSOH & ROH components based on estimated tube metal temperature and other inspection data;
  • Reviewing & analysing previous failures, inspection and maintenance data for other pressure parts (i.e. economiser, etc) of the boiler to complete the life assessment study;
  • 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 about of Remaining Life Assessment & Extension 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.

Launch of a new Group Sponsored Project on Aberrant P91 Inspection, Repair and Life Extension

ETD Proposal No: 1558-gsp-prop17

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

ETD has launched a new proposal for a Group Sponsored Project. The proposal is entitled 'Early Stage Damage Inspection, Repair & Life Extension of Aberrant P91 Components'. This newly launched proposal is aimed at testing some of the NDE techniques, tried and established in the earlier project, on the P91 aberrant microstructures, It is also looking at testing some newer NDE techniques developed since the start of the earlier project, and, also look at new ideas and technologies for the strengthening and life extension of P91 components which have either developed creep damage or contain aberrant microstructures.

As this is a Group Sponsored Project (GSP) costs are shared between a number of sponsors so each pays only a fraction of the total project cost. 

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

Recent Completed Project on ‘Risk Based Inspection and Remaining Life Assessment of a Boiler for an Asian Power Plant’

ETD were approached to submit a proposal on ‘Risk Based Inspection (RBI) and Remaining Life Assessment (RLA) of one of the client’s boilers by performing on-site inspection, analysis and assessment on tubes, T-piece nozzles, stub tube weldments and hot reheat pipe weldment for FSOH and ROH.

The work involved performing on-site inspections - ultrasonic measurements (UT) of tube wall & bore oxide scale thickness, replication, hardness measurement, wet fluorescent magnetic particle test and advance UT phased array of selected components from FSOH and ROH. The inspection data was then used to estimate tube metal temperature and identify material degradation. This was then used for damage assessment and predicting the remaining life of outlet headers and tubes of final superheater and reheater. The previous inspection and maintenance data for other pressure parts (i.e. economiser, etc) were also reviewed and analysed to complete remaining life assessment of the boiler.

For more information about ETD’s Remaining Life Assessment services, please click here.

Recent Completed Project on ‘Accelerated Rupture Testing and Integrity/Life Assessment of Cold Formed Bend Material’

In a recent outage in a high temperature plant in Asia, creep damage was found on certain cold formed bends. An assessment of replicas concluded that the damage was indicative of creep in its tertiary phase and the bends were removed from service. A subsequent metallurgical examination of the cross-section of the bend was carried out. The findings suggested that damage was not as severe through-wall as had been observed in the replicas.

remaining life assessment.jpg

Alignment of the cavities was less severe. Therefore, ETD was approached with a request to perform accelerated creep testing to provide an estimate for the remaining life of the material. This was used to make run/replace decisions on such components. For more information about our life assessment services please click here.

Root Cause Failure Analysis and Remaining Life Assessment of CO Reformer Tubes

ETD carried out Root Cause Failure Analysis and Remaining Life Assessment of CO Reformer Tubes for a Petrochemical Plant. It is reported that the failures occured at catalyst tubes and flexi tubes of the CO reformer section.

The scope of work carried out included:

  • Visual examination of all tube samples including internal deposit and external appearance;
  • Assessment of condition of the tubes inner & outer surfaces and bulged areas;
  • Dimensional examination of the tube samples to examine diameter growth;
  • Chemical analysis of base material to determine the chemical composition of the tube material to establish actual material constituents;
  • Metallographic examination of the tube samples using optical microscopy to assess the condition of internal and external surfaces and also to identify the damage mechanism(s) (i.e. creep, carburization, localized heating or others);
  • Metallographic examination of two tube samples (two worse tubes will be selected based on visual examination) using SEM (Scanning Electron Microscope) to confirm the damage mechanism(s);
  • Mechanical testing (Hardness & Tensile 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;
  • Basic review of design drawings, operating parameters, previous failure and maintenance history.
  • Root Cause Failure Analysis (RCA) based on the findings of above investigations.
  • Measurements of the thickness of tube internal oxide/scale to determine the actual operating temperature;
  • Assessment of tube remaining life based on the estimation of actual tube operating temperature and the data from published literature;
  • A report covering results of investigations, RCA & RLA analysis and recommendations for any further actions to be taken for safe operation of the components.

For more information about our Failure Analysis & Remaining Life Assessment services, please click here.

Risk Based Inspection and Remaining Life Assessment of a Boiler for a Power Plant

ETD recently performed Risk Based Inspection and Remaining Life Assessment of a Boiler for a Power Plant in Europe.

The work carried out included: 

  • Reviewing the drawings of FSOH & ROH, tube banks of the boiler to be studied and identifying accessible test locations for on-site inspections.
  • Performing on-site ultrasonic thickness (UT) measurement of tube wall thickness and bore oxide scale considering 50% of total tubes for FSOH & 40% of total tubes for ROH;
  • Performing on-site replication and hardness measurements on straight tubes, T-piece nozzle weldments, stub tube weldments and hot reaheat pipe weldment for FSOH & ROH;
  • Performing on-site wet fluorescent magnetic particle tests on T-piece nozzle weldments and stub tube weldments for FSOH & ROH;
  • Performing on-site advanced UT phased array on T-piece nozzle to main steam pipe weldment for FSOH and hot reaheat pipe weldment for ROH;
  • 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;
  • Assessment of damage and material degradation of outlet headers, tubes, T-piece nozzle weldments, stub tube weldments and hot reaheat pipe weldments for FSOH & ROH based on the replication and hardness measurements data;
  • Review and interpretation of wet fluorescent magnetic particle tests data and UT phased array inspection data to assess any presence of surface and/or internal cracks/ defects;
  • Reviewing & interpretation of UT inspection data and estimation of wall thickness loss & tube metal temperature;
  • Assessment of the remaining life of FSOH & ROH components based on estimated tube metal temperature and other inspection data;
  • Reviewing & analysing previous failures, inspection and maintenance data for other pressure parts (i.e. economiser, etc) of the boiler to complete the life assessment study;
  •  Preparing a full report including the results of on-site inspections, analysis results of damage & life assessment study and make recommendations for any further actions to be taken by the client for safe and reliable operation of the boiler.

For more information about our Risk Based Inspection & Remaining Life Assessment services, please click here.