Recent Completed Project on Inspection, Fitness for Service and Life Assessment of T-piece Welded Piping


ETD is pleased to announce the successful recent completion of an inspection, fitness for service and life assessment project for a European based plant.

In October 2017, microcracks were observed on a welded T-piece of main steam balancing pipe connections. Defect/ crack assessment was performed by the plant engineers and the results showed that the component will be fit for service for another 4 years with the repair of cracks by burring techniques. However, these results were not acceptable by the owners and insisted further analysis would be performed. The results of the second assessment showed that the component should be replaced as early as possible. Due to the disagreement between the owners and plant management, a decision was made that further analysis would be performed by an independent third party and then make appropriate decision for run/repair/replacement of the component. Therefore, ETD were asked to submit a proposal to perform further inspection and analysis to assess fitness for service and predict remaining life and of the component.

ETD proposed to carry out the project in the following two phases. The objectives and scope of work for each phase are:

Phase 1:

(i) Review two previous reports - defect assessment and life assessment reports completed by the client.

(ii) Perform onsite inspection. This will include the followings:

  • On-site replication at 4 clock positions for the affected T-piece of the balancing pipe connection;

  • On-site hardness testing at the same locations as the replication spots;

(iii) Review design and operating parameters, previous failure and maintenance history;

(iv) Perform condition assessment and fitness for service assessment based on the damage classification.

(v) Report covering the results of the investigations & provide recommendations on whether the component is fit for service.

Phase 2:

(i) Perform pipeline stress analysis of the piping system to obtain line loads and bending stresses which will be used in Finite Element (FE) analysis. This will include the following Tasks:

  • Review of design/ isometric drawings clearly showing all dimensions and piping connections of the piping system.

  • Review and analysis of inspection data/ information of hangers and supports collected during hot and cold condition inspection.

  • Perform pipeline stress analysis of the piping system using CAESAR II software.

(ii) Perform Finite Element (FE) analysis to obtain accurate stress levels at the affected T-piece location of the balancing pipe.

(iii) Perform remaining life assessment using the stress values obtained from FE analysis.

A report was then issued detailing the findings with photographic records including results of stress analysis & life assessment and highlighting any possible causes for concern regarding the pipe integrity. Furthermore, the report included recommendations for possible remedial actions that may improve component integrity.

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

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.

ETD's ‘HIDA-7’ Conference – Special Issue now published in the ‘Materials at High Temperature’, journal

ETD Consulting are pleased to announce that following its successful High Temperature Defect Assessment (HIDA-7) Conference on the subject of Life/Crack Assessment and Failures in Industrial Structures, in particular those operating at high temperature, which was held at Portsmouth University in May 2017; edited versions of several of the papers presented at this conference have now been published in the ‘Special Issue of Materials at High Temperature’ journal.

HIDA was originally the acronym for an EU Commission and Industry supported research project, led by Dr Ahmed Shibli of ETD, which aimed to develop a unified European High Temperature Defect Assessment procedure. The Brite-Euram HIDA project involved 11 organisations from 7 countries, with the effectiveness of the procedure developed being demonstrated using material models based on data generated and/or gathered on a number of CrMo(V), 9CrMoVNb and 17Cr12NiMo engineering steels. The original HIDA conference held at CEA (Saclay) in 1998 focused on the themes covered by the Brite-Euram project, and in particular topics concerned with crack growth and accurate assessment of the behaviour of high temperature plant components containing defects and operating under steady and/or cyclic loading conditions. The scope of subsequent HIDA conferences was extended to the consideration of aspects relating to life assessment and condition monitoring, integrity of repaired welds and the characteristics and performance-in-service of newer advanced martensitic steels such as P91 and P92.

The 22 papers included in MHT’s HIDA-7 Special Issue fall under the themes:

  • Deformation and crack growth and their modelling;
  • Life assessment and condition monitoring;
  • Advanced martensitic 9/10%Cr steels;

To read the full-depth article from the special issue of materials at high temperatures magazine, please click here.