Contents

Updates on Recent Group

Sponsored Projects (GSPs)

Third Party Failure

Analysis Projects

Third Party Life

Assessment Projects

ETD’s 2017 Upcoming

Events

Electrical Discharge Sampling

Equipment (EDSE)

Scanning Force Microscope

(SFM)

ETD’s Outage Services

January 2017 New Technologies for High Temperature Plant Inspection, Repair

and Life Assessment - particularly for P91/ P92 components ETD is pleased to announce an exclusive partnership agreement with Chugoku Electric Power Company (CEPCO), Japan. ETD can now offer patented technologies for the inspection, monitoring and life extension of high temperature plant components. (references and details can be provided on request):

Photo: Meeting of ETD Staff with CEPCO Management to sign collaboration agreement.

ETD Technology Newsletter

LHS: Life consumption versus operating hours for a seam welded creep damaged P91 pipe - with Obikou (blue line) there was no new creep cavitation (RHS) and the remaining life was increased by a factor of 4 - compared to ‘without Obikou’ (red line). Contd.

Obikou reinforced pipe bend

1) Technology for reinforcing seamless or seam welded pipelines, pipe bends etc.

The Technology is known as ‘Obikou’ or ‘Bandage Reinforcement Technology’ and is offered for reinforcing creep damaged pipelines by simply and quickly winding an alloy strip at site, in order to improve the creep strength of straight, bent, or seam welded high temperature pipes. The method is applicable to steel pipe including P91, P92 and other high temperature steels. Both R&D and plant experience has shown that residual life can be extended by a factor of 4.

VVa

Various flange type pipeline reinforcements

P22 pipes tested under internal pressure creep. Pipe without Obikou burst in 256h, the one with Obikou burst in 1597h. Life was extended by more than a factor of 6.

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2) Technology for reinforcing butt welded pipelines and Tee Pieces using flange type sleeve fixtures

This technology provides pipeline reinforcing by preparing a sleeve fixture of a flange type. The fixture can be simply and quickly attached on site, in order to improve the creep & fatigue strength of a butt welded section of a high temperature pipeline. The flange type fixture is fabricated by first obtaining geometric data for the pipeline section to be reinforced by on-site 3D scanning (see later) during a plant outage. The fixture is then attached during the next outage.

A Tee Piece reinforced using a sleeve fixture of a flange type

3) Measuring pipeline displacements at hanger locations using a ‘Total Station’ instrument for input to pipeline stress models – to identify pipeline components at higher risk of damage

A ‘Total Station Theodolite’ is an optical laser instrument used to survey the distance and slope between two points. This instrument can accurately measure 'hot to cold' pipeline displacement at hanger supports, from measurements obtained when the plant is both hot (online) and cold (offline). Measurements can then be input to 3D pipeline stress models, in order to analyse operating stress levels – thus allowing identification of pipeline components that are at higher risk of damage, and enabling targeted inspections.

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Contd.

The above four technologies can be deployed and supported with detailed Finite Element Analysis (FEA) modelling and other life assessment techniques.

These new developments combined with the use of ETD’s newly developed and demonstrated portable SFM Microscope, and other NDE techniques developed/ demonstrated (some described later), offer a unique opportunity for the inspection & life assessment of high temperature and other industrial components.

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- For more information and back up data/ references on any of the aforementioned technologies

please contact us.

January 2017 ETD Technology Newsletter

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Contd.

4) Assessing residual life of weldments for P91, P92 and other alloys using innovative laser strain gauge

Residual life of pipeline weldments can be assessed based on strain measurements made across the weld using a laser displacement meter. The laser meter is attached to the pipe with a baseplate which is tack-welded along with a reflector plate (see below). During outages, the laser meter is then temporarily installed to obtain accurate strain measurements, which can then be analysed to assess damage accumulation and residual weld life. Only one laser device is needed to monitor damage at many locations. The laser technique thus offers high accuracy and reliability for strain measurement cross-weld or at other positions - much more economical than conventional strain gauges.

A 3D Scanner can be used onsite to measure detailed geometry for various components, for example, to generate pipe system isometric drawings and 3D Engineering CAD models. The 3D scanner acquires three-dimensional component geometry by optical laser technique. Onsite surveys by 3D scanning may typically be required for performing detailed stress analysis by FEA. ETD and its associates are now offering such services for high temperature pipeline life assessment.

If you would be interested in discussing potential projects further please contact us at: enquiries@etd-consulting.com +44 1372 363111

ETD Technology Newsletter January 2017

ETD engineers undertaking a comprehensive training in the use of Obikou (left- demonstration in the Workshop) and other new laser based technologies for pipeline and weld strain monitoring and remaining life assessment.

TRAINING of ETD ENGINEERS

======================================================= ETD’s SPECIALISTS AREAS: These include Gas Turbine Components Failure Analysis, Crack Assessment, Power Plant Cycling, Power Plant Cost Analysis & Benchmarking, P91, P92 Steels, and more. ETD has now built up a reputation in offering the above services to clients worldwide. ETD has developed its own software and methodologies for some of the above and can thus offer unique services. Its Cost Analysis programme, both for base load and cyclic power plants, is quite unique and has built up a reputation of its own. ETD has developed its own database both for conventional and CCGT power plants and has been offering these services to plants in the USA, Canada, Europe and Asia. ETD has similarly Benchmarked a number of plants for its client utilities to compare plants with each other within their own fleet and with the ETD large database, in terms of key performance indicators (KPIs) such as forced and planned outage rates, O&M costs, efficiency, availability, reliability etc. For P91 and P92 steels, which are relatively difficult to inspect and forecast their safe operating life, especially during the early to mid-stage of the life, ETD has developed its own equipment (such as the portable Scanning Force Microscope – see later) to make this possible. Similarly both for low and high temp. crack assessment ETD has developed its own crack assessment software known as ‘Crackfit’ which is available for purchase but is also used by ETD to provide services to its clients worldwide.

Updates on Current Multi-Client or Group Sponsored Projects (GSPs) On this page you will find details of ETD's active GSPs. As GSP costs are shared between a number of sponsors so each pays only a fraction of the total project cost. We are always open to new sponsors. All GSPs are open to new Sponsors. Reliability Issues with Gas Turbines Operating in Baseload and/ or Cycling Modes The overall objective of this project is to identify issues with the operation of open (or simple) cycle and combined cycle combustion turbines and provide information, methodologies and guidance on ways to address reliability and performance problems. ETD will therefore perform a detailed evaluation of the technical factors and issues that impact the performance of a range of combustion turbine models, including impacts of a range of operating conditions both for base load and cyclic operation. ETD has a good background in this as it has carried out similar work for its clients in North America and Europe. 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. Protection & Preservation of Compressors in Gas Turbines With the initial group of sponsors secured ETD is now planning to start work on a new Group Sponsored Project (GSP) which should be of interest to the Gas Turbine industry worldwide. The idea comes from the problems faced by some of the ETD clients and the work that ETD is conducting on compressor damage analysis and its effect on GT integrity and efficiency. The outcome of this project can save the participating industry/sponsors millions in terms of improving plant efficiency etc. as explained in the full proposal. Costs for the project sponsorship and project details (full proposal) are available on request. WELDLIFE - Avoidance of P91 Type IV failure in P91 and P92 Steels This new 5-year duration project deals with the changing of the heat treatment cycle of P91 welding and some changes to the welding processes which research by Japanese researchers and a UK project led by industry has shown to increase the rupture life of such weldments by a factor of 2 to 3. The project has presently been promised support by UK and Japanese companies but we need more sponsors to start the project. The full proposal/ project outline can be supplied on request. Creep Rupture Strength of Abnormal P91 Materials & Welds This 5-year duration project, is aimed at generating long-term creep rupture data urgently needed to help plant operators establish safe operating life of aberrant or abnormal P91 base and weld metal microstructures often found in many power plants around the world. These aberrant materials and weldments arise when heat treatment of P91 components, during steel production or component fabrication, is not carried out to the precise requirements that need to be met for P91. As a result of incorrect microstructure creep rupture strength can be much lower than that of normal material, leading to early failure. Currently, ‘sighter’ tests are being carried out to establish stress levels required to generate long-term data, so this is a good time for new sponsors to join and benefit from the results. Although not envisaged at the start of the project, it has been found that this work is also helping to recognise high temperature behaviour of aberrant microstructures and establish new inspection regime for P91 and P92 components.

(Continued on next page)

January 2017 ETD Technology Newsletter

Updates on Group Sponsored Projects (GSPs) – Contd. Development of Inspection, Monitoring & Life Assessment Technologies & Guidelines for P91/P92 in-service components In this 3-year duration project three P91 and one P92 welded pressure vessels are being tested under creep conditions for 10,000 hours. These tests are being interrupted at 30, 50 and 70% of estimated life to enable the inspection and study of damage development using various inspections techniques (replication, hardness, innovative UT techniques, boat sampling using ETD’s EDSE equipment, portable Scanning Force Microscopy, magnetic property measurements and AC and DC potential drop techniques. Some of the pressure vessel tests have now been completed together with the supporting cross weld rupture data and FE analysis. Relationships between damage in the ‘Type IV’ or fine-grained region of the HAZ and the remaining life of the welded components are being developed. These relationships are urgently needed to help plant operators manage the life of welded P91 components. This project involves partners from UK, Germany, Italy, Belgium, USA and Japan. The project is expected to be completed by April 2017.

========================================================================================= NEW PARTNERS ARE WELCOME TO JOIN GSPs at any stage of the project.

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Have an idea for a new Group Sponsored Project? ETD has excellent expertise in plant services and technical consulting backed up with its R&D which is conducted in collaboration with plant manufacturers, plant operators, service providers and researchers from around the world. The company is thus in an ideal position to conduct such projects for industry sponsors and bring together plant experience from best run plants and the latest technology developed in Europe, Japan, USA and elsewhere. In response to the needs of the international industry, ETD Consulting regularly launches new multi-client or joint industry projects for participation by organisations from around the world. The benefit of joining these GSPs, in which costs are shared, is that each participant gains the results of the whole project at a fraction of the full project cost. The work is carried out by ETD experts and its consultants - with some information, expertise or data contribution by the participants/ sponsors on a voluntary basis. If you feel that you have a problem that is either too costly to solve on your own and/or needs expertise from outside then please write to us to discuss the possibility of a Group Sponsored Project (GSP) on the topic of interest to you.

January 2017 ETD Technology Newsletter

ETD’s GUIDELINES AND REPORTS – 50% Price offer during January and February 2017 Limited Time Offer: ETD is now offering all of its Reports / Guidelines at 50% of the announced price for a limited time. This will only apply to orders received and paid for during the months of January and February 2017. Please click here to see the list of Reports. The list contains live links to see the report contents and other details.

January 2017 ETD Technology Newsletter Examples of ETD’s Recently Completed Third Party Failure Analysis Projects

ETD has extensive knowledge and experience of damage mechanisms and failure root cause analysis of systems operating in power plants. For more information about ETD’s Failure Analysis services, please click here.

ETD are pleased to announce the successful recent completion of various failure analysis projects, examples can be found below, please click on the titles for more information:

1) ‘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. Therefore, ETD was approached with a request to perform accelerated creep testing to provide an estimate for the remaining life of the material.

2) ‘Failure Analysis of HRSG High Temp. Superheater (HPHTSH) and Reheater Outlet Header Tubes’ Following the client’s recent tube failures close to tube-to-header connections in their High Pressure High Temperature Superheater (HPHTSH) Outlet Header, ETD were invited to submit a proposal to carry out failure analysis of T91 tube samples removed from the failed area. The work involved performing tube failure analysis study based on laboratory testing and assessment of two removed tube samples.

3) ‘Investigation of Cracking Damage to a Gas Turbine Compressor Blade’ During a recent outage, gas turbine inspectors of a CCGT noticed cracking damage in one of their compressor blades. ETD was requested to carry out investigation of cracking damage. ETD was supplied by the client with one failed compressor blade (cracked) and one un-cracked compressor blade.

ETD carried out the following work: • Visual / macroscopic examination including the recording of the blade dimensions. • Microscopic examination of the general surface condition and the cracking damage in the blade sample to help identify the damage mechanism e.g. fatigue, corrosion, impingement damage etc. • Chemical analysis of deposits using EDX. • Analysis of the base material chemical composition. • Fractographic analysis of the fracture surfaces to identify the damage mechanism, using SEM (Scanning Electron Microscope) coupled with findings of visual examination, optical microscopy and chemical analysis. • Identification of potential causes of the damage and the source of any contaminants. • Estimation of the remaining life for the un-cracked blade, using fatigue life assessment according to EN12952 standard. Observations from the other analyses was used to assess the blade material condition and to refine the life assessment results. • A report was submitted to the client based on the investigation of the cracking damage with photo documentation, including (i) analysis of the risk of continuing to run the GT, and (ii) recommendations for remedial actions to avoid or minimize the risk of damage recurrence to the GT units.

If you would like us to provide a quote on solving problems that may have arisen at your plant please don’t hesitate to contact us at: enquiries@etd-consulting.com

ETD Technology Newsletter January 2017 Examples of ETD’s Recent Plant Inspection and Life Assessment Projects

ETD are pleased to announce the successful recent completion of various plant inspection & life assessment projects, examples can be found below, please click on the titles for more information:

1) ‘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.

2) ‘Pipe Hanger Inspection & Stress Analysis of Piping Systems’ - for a Conventional Power Plant ETD was contacted to study some of the hangers of the client’s existing unit. The client’s management expressed interest in performing pipe hanger inspection including stress analysis, inspection methodology & recommendations for this Unit. ETD carried out the following work: • Review of Relevant Piping Documents • Perform Hanger Inspection (Hot & Cold walk-down) • Piping & Hanger Inspection Data Analysis • Piping System Modelling and Stress Analysis • Results Analysis and Validation • Training in Pipe Inspection, Data Analysis and Stress Analysis • Recommendations and Submission of the Final Deliverables • Presentation of Final results. For more information about ETD’s Stress Analysis services, please click here.

ETD’s 2017 Events Diary

We also offer in-house Training Courses on a wide variety of power and process plant issues. For more information click here.

15-17 May 2017 (HIDA-7 Conference + Optional Training Course ) 3-DAY CONFERENCE ON LIFE/CRACK ASSESSMENT & FAILURES IN INDUSTRIAL STRUCTURES + 2-DAY COURSE (18-19 MAY 2017) ON CRACK ASSESSMENT IN INDUSTRIAL COMPONENTS UNIVERSITY OF PORTSMOUTH, UK

CALL FOR PRESENTATIONS/ PAPERS: 11-12 October 2017 2-DAY CONFERENCE ON FABRICATION & USE OF P91 STEEL + 2-DAY TRAINING COURSE (9-10 OCT 2017) ON P91 & P92 ISSUES CAIRNS, AUSTRALIA

January 2017 ETD Technology Newsletter

CALL FOR PRESENTATIONS: 11 April 2017 EPERC 1-DAY SEMINAR - NEW APPROACHES TO NON-DESTRUCTIVE TESTING AND INSPECTION OF PRESSURE EQUIPMENT ROME, ITALY

24-27 April 2017 4-DAY PRESSURE VESSEL AND HEAT EXCHANGER DESIGN COURSE LONDON, UK

EDSE – Innovation in ‘Boat Sampling’ The Electric Discharge Sampling Equipment (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. ETD has recently used EDSE for the sub-surface material characterisation and quality checks of new and in-service P91 components. 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.

Industry Need The most accurate way of determining an aged material’s condition is through non-destructive, physical testing. For a large plant component, this is obviously impossible without taking a sample. Without care, this sample can leave the component damaged with stress concentrations and a reduced wall thickness, shortening the service life.

The Solution Based on the EDM process, the EDSE cuts out small, thin section of samples; leaving no sharp corners and without inflicting work hardening on the component surface. These samples can then be machined down to be used in creep, fatigue, tensile, toughness and hardness tests. The EDSE can cut out small slices between 1 to 20 mm thick and approximately 20mm2 or 40mm2 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.

Advantages of EDSE An advantage of the EDSE system is that the resulting cavity leaves rounded edges with a 4mm radius and no stress concentrations. The process of cutting uses a consumable electrode that removes material via electric spark erosion, with purified water to remove debris and provide a cooling medium. 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.

This is a picture of a boat sample that can be cut out of your pipe. The maximum depth our electrodes can go is

20mm in depth, 20mm width and 35mm in length.

For more information on the Electrical Discharge Sampling Equipment, visit www.etd-consulting.com/edse

This is a video from a job we recently completed for a client. in Europe. The EDSE was mounted on a turbine rotor using magnetic mounts and a bespoke frame.

Client Feedback “We were pleased to be able to use the scoop sampling technique on this rotor and believe there is a potential for use elsewhere. We were very pleased with the results as we have been able to provide substantially more information on the crack mechanism than we would have been able to do with surface metallography.” Feedback from a European Turbine Manufacturer - for work on their steam turbine rotor. This involved cutting out samples up to 20 mm thick to investigate the root cause of crack initiation and propagation

EDSE is available for purchase or as part of ETD’s inspection services. For further details or to request a demonstration please contact us.

ETD Technology Newsletter January 2017

A Portable Microscope for On-Site Use in Multiple Industrial Sectors – Power, Process, Aerospace etc. - for damage and microstructure studies More Powerful than an SEM !

The image on the right shows the microscope scanning head (square box in the centre) mounted on a mobile frame that sits on a fixed frame which in turn is attached to the component under investigation.

What is I-SFM? SFM or I-SFM is a portable version of the Atomic Force Microscope that has been developed for on-site damage and microstructural imaging of critical components in industry or other large structures – metallic or non-metallic.

Advantages Over Current Tools SFM has the following significant advantages over the other NDT and diagnostic tools currently in use:

• SFM can be used on-site and attached directly to the component being investigated after polishing the area under study to 1 micron level (same as for replication) and etching.

• The ability to view defects in 3D at the nanometer scale (with sizes of the order of 0.01-0.1 microns) allows for early-stage damage detection that would not be picked up by most other NDE techniques. Thus very useful for P91 type in-service component investigation where micron size creep cavitation develops only late in life and thus early damage can be missed by most NDE techniques.

This video shows the microscope mounted on a mobile frame that sits on a fixed frame which in turn is attached to the component under investigation.

Scanning Force Microscope (SFM)

ETD Technology Newsletter

SFM images acquired before (top) and after chemical etching of a P91 sample, sowing creep cavities.

A revolution in non-destructive on-site examination and testing of industrial components and materials for nano or micro level defects, microstructural deterioration and other microstructural properties.

SFM mounted on a pipe. Once mounted the SFM movement and scanning is controlled by a laptop which displays and stores the material defect and microstructural images/ features.

Three dimensional image a creep cavity

(Continued on next page)

January 2017

SFM is available for purchase or as part of ETD’s inspection services. For further details please contact us.

Latest Scanning Force Microscope (SFM) News (Contd.)

ETD Technology Newsletter

SFM is now in the Group Sponsored Project ‘P91-P92 Inspection and Life assessment’. It is another one of ETD’s promising inspection techniques. This project is briefly described somewhere else in this Newsletter. Large pipe (315mm dia x 25mm ‘t’) tests are boing conducted on welded P91 and P92 seam and butt welded pipes under high temperature (600 and 625 deg. C) and pressure, and in some cases under tensile/ end load. These tests are being stopped at the durations of 20, 40, 70 and 100% of the estimated pipe lives and various innovative NDE techniques being tested and demonstrated and damage thus observed related to the remaining component life. An example of the results of the SFM study is shown below.

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Top two photos: Tests being performed on circumferential and seam welded P91 and P92 pipes. Bottom Figure: Volume fraction of cavities versus life consumption as shown using the SFM on the above test pipes.

January 2017

Need Help With Plant Outage Services? Benefit from our Specialist Expertise in P91 and P92

The advantage of ETD over others is that we can conduct both on-site services and post-outage life assessment work. Whether your need is for one-off replication services, other on-site services or life assessment - or if you want one group to design, manage and run your entire outage and life assessment process - ETD can assist. We can offer the following –

(1) Pre outage planning and management • Includes detailed technical analysis of historical operations and maintenance data, plant drawings etc. • Provides you the best outage plan, with the right tests at the critical test sites for your plant needs, to maximise the usefulness of any outage work.

(2) Outage management and operations • You provide the safety training and plant orientation, we provide, manage and co-ordinate the testing teams, to ensure a smooth outage.

(3) Provision of on-site services • Includes all NDT (visual inspection, metallographic replication, electrical discharge sampling, boroscopy, hardness testing, ultrasonic testing, phased array testing, magnetic particle testing, penetrant testing, remote field eddy current testing, rotational inspection etc). • For sampling, our own unique NDT equipment (Electrical Discharge Sampling Equipment, or EDSE), developed in collaboration with international partners in Japan, leaves cavities with rounded edges that do not usually require repair - this revolutionises the cutting process. • For early stage damage detection such as creep cavitation ETD can use our unique Integrity Scanning Force Microscope (I-SFM). This is a portable version of the Atomic Force Microscope, which has been designed by ETD (in collaboration with industry partners) for on-site use. It can be attached directly to metallic or non-metallic components during your outage and detects creep cavitation at the nano scale, producing real-time data and 3D images for analysis.

(4) Post-outage analysis services and reporting • On all issues including life assessment (deterministic or probabilistic), failure analysis etc. • Can include advance planning based on the above for future outages, development of operations & maintenance plans.

If you would be interested in discussing potential projects further please contact us at: enquiries@etd-consulting.com +44 1372 363111

ETD Technology Newsletter January 2017