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ETD Consulting, Fountain House, Cleeve Road, Leatherhead, Surrey, KT22 7LX, UK
Tel: + 44 (0)1372 363 111 Fax: + 44 (0)1372 363 222 [email protected]
www.etd-consulting.com BS EN ISO 9001: 2008 Certified ETD Consulting is a trading name of European Technology Development Ltd, Registered in England No: 3553836
ETD\PPp1:Feb17
CRACKFIT – Defect Assessment Tool for Boilers/ Pressure Vessels & Turbines
TECHNICAL PROPOSAL
ETD Proposal No: 1576-tp-prop17
Proposal for a Group Sponsored Project (GSP)
Proposal by:
F Akther, Dr D Robertson
Contact Name: Dr A Shibli
Phone: + 44 1372 363 111
Fax: + 44 1372 363 222
Email: [email protected]
July 2017
2
CONTENTS
1. INTRODUCTION ........................................................................................................... 3
2. OBJECTIVES ................................................................................................................. 5
3. SCOPE OF WORK ......................................................................................................... 5
4. PROJECT BENEFITS .................................................................................................... 7
5. TIMESCALE & DELIVERABLES ............................................................................... 9
6. PRICE ESTIMATE AND CONDITIONS ..................................................................... 9
7. ETD’s TEAM FOR THIS PROJECT .......................................................................... 10
8. FURTHER CONTACTS............................................................................................... 10
APPENDIX 1: ETD’S PROFILE ........................................................................................ 13
APPENDIX 2: ETD’s STAFF & EXPERTISE ...................................................................... 16
APPENDIX 3: ETD’S EXPERIENCE AND CAPABILITY ................................................. 18
3
1. INTRODUCTION
Defect assessment procedures aim primarily to avoid component failure during service, avoid
early replacement and thus incur capital expenditure only when absolutely necessary.
Components operating under stress and at elevated temperatures are likely to be subject to in-
service damage, in the form of crack initiation and growth. Once found it is important to
understand how long a crack can remain safely in service.
ETD, initially as a part of the European Commission project HIDA (High-temp. Defect
Assessment) and later as a joint-industry project, has brought together various recognized
national and international defect assessment codes and practices and developed a practical
defect assessment tool named ‘CrackFit’. This tool is a software that is designed to help
engineers perform crack initiation and growth assessment both for low and high temperature
components. Crack initiation and growth for a host of components (pressure vessels, plate and
laboratory specimens) and commonly occurring crack geometries found in industrial plant are
incorporated in this software. Crackfit functioning has been checked and verified by
independent experts against hand calculations and other in-house procedures. CrackFit is
accompanied by a large material and creep and fatigue (representing various operation modes
of a flexible operation power plant/ HRSG) crack growth database. It thus represents the
cutting edge in crack and defect assessment software and is already being used by a number of
power and processing industries in Europe, North America and Asia.
This proposal is about adding to the CrackFit software (developed for boilers, pressure
vessels/ piping and lab. specimens only) cracks commonly found in power plant turbines.
2. FEATURES OF THE ‘CrackFit’ SOFTWARE
Features
A complete coverage of Crack/Defect Assessment Procedure developed specifically for
high temperature industry use.
Reliably measures crack initiation and growth using fracture mechanics concepts.
The fitness-for-service program incorporated into the software performs calculations to
determine a defect’s criticality in line with the assessment codes.
A verified procedure and software with a very useful and detailed database for the
assessment of cracks in the power, petrochemical, refining or other high temperature
plant.
Ability to expand the range of component/ defect geometries.
Carries out both deterministic and probabilistic crack assessment.
Assessment Modules
The specific modules which are incorporated in CrackFit software are: Materials, Cyclic
loading and Leak-Before-Break (LBB) modules as discussed below:
The Material module allows the user to select different materials relevant to the component to
be assessed. The material properties included are tensile strength, stress rupture, rupture
ductility, fatigue and creep crack growth data from established sources like British Standard
BSi PD5500, HIDA and ECCC (European Creep Collaborative Committee) datasheets. Two
4
example materials (P91 base metal and P22 forged base metal) are already included in the
software. A number of other materials such as: martensitic steel ASME P91; traditional low
alloy steels P22 and P11, turbine rotor and casing steels such as 1CrMoV forged and cast;
austenitic steels such as 304 and 316 and a number of other materials are included in the full
database which can be purchased separately or as a part of the CRACKFIT Software, if
required. This database also contains the weld metal and HAZ data where necessary.
The Cyclic Loading module provides algorithm for the user to apply up to four scenarios of
cyclic loading of different maximum and minimum load, temperature and dwell time values for
the case of creep-fatigue interaction. The cyclic loading can be performed until the component
fails or until the maximum time specified is reached. This Remaining Life Assessment (RLA)
feature provides recommendations for run/repair/replace decisions.
The Sensitivity and Probabilistic analysis; In reality, input data required for the defect
assessment can be varied and may be obtained from well scattered data tending to produce
large deviation of the input values, hence reducing the confidence in the quality of the results.
CrackFit accommodates the two types of analyses by allowing the user to simply choose the
confidence level for different type of input data. The outcome of the evaluation (such as ‘time
to failure’, ‘cycles to failure’, ‘number of cycles required for a certain crack growth’ etc.) is
represented in CrackFit in a simple tornado or bar diagram for the sensitivity analysis case and
the ‘probability of failure versus time’ curve can be derived from the probabilistic analysis
using the Monte-Carlo Simulation.
Crack geometry
FAD Diagram shows the crack growth
Fig. 1: Example of ‘Crackfit’ features
3. PROPOSED NEW DEVELOPMENT INCORPORATING TURBINES
CrackFit is designed to be a dynamic and flexible tool. The software has been designed to
allow the expansion of its contents in terms of adding new geometries that an owner may like
to add for his specific plant.
This proposal is about the further development and expansion of the CrackFit software by
adding new geometries for power plant Turbines.
Failure assessment diagram
0.00E+00
2.00E-01
4.00E-01
6.00E-01
8.00E-01
1.00E+00
1.20E+00
0 0.2 0.4 0.6 0.8 1 1.2 1.4Sr [-]
Kr
[-]
Path - Depth
Path - Surface
Initial flaw - Depth
Initial flaw - Surface
Final flaw - Depth
Final flaw - Surface
Assessment curve
5
4. OBJECTIVES
The main objective of this study is to expand CrackFit software by adding geometries for
cracks in Power Plant Turbines.
The detailed project objectives are as follows:
1. Sponsors’ interest and approval on the number of new crack geometries to be added;
2. Perform analysis and prepare appropriate solutions for the specific geometries;
3. Expand CrackFit software with the addition of the new geometries;
4. Perform software test and validate it for the expanded version;
5. Submit final deliverables (‘CrackFit’ software) to the project sponsors in a CD with
installation instructions.
5. SCOPE OF WORK
The existing version of CrackFit contains a number of boiler component (straight pipe, T-piece,
nozzle and elbow), test specimens (CT & SENT) and crack geometries and configurations
(such as embedded, surface emerging etc. cracks). In total, it contains 17 geometries.
With regards to the expansion of ‘CrackFit’ to include new geometries of interest to the client
the scope of work would involve:
1. Writing the specification of the crack geometries in relation to the all required inputs
and solutions for the calculation of Stress, Stress Intensity Factor, Reference Stress and
Limit Load solutions.
2. Integration of analytical solutions into ‘CrackFit’ Software Programme.
3. Verification first by ETD and then by independent specialists using manual spreadsheet
calculations.
Proposed turbine component geometries:
As a first step ETD proposes the following four crack geometries to be added, based on
available solutions for the specific geometries.
Note: Solutions are also available for some of the other geometries of round bars – straight-
fronted flaws, semi-circular surface flaws and semi-elliptical surface flaws. The project
sponsors are welcome to choose these additional geometries or other geometries of interest to
them with additional costs that can be discussed.
6
i) Quarter elliptical crack at bore corner
Fig. 2: Schematic of ‘corner flaw at hole’ geometry
ETD will apply BS7910 and FITNET (R6) defect assessment procedures for quarter and/ or
double quarter elliptical crack at bore corner to prepare the analytical solutions which will be
integrated into the software.
ii) Semi elliptical crack at bore surface
Fig. 3: Schematic of surface flaw
ETD will apply BS7910 and FITNET (R6) defect assessment procedures for semi elliptical
crack at bore surface to prepare the analytical solutions which will be integrated into the
software.
Note: This geometry assumes to be the closest geometry to the semi elliptical crack at bore
surface.
7
iii) Buried elliptical crack in bore cob
Fig. 4: Schematic of embedded flaw
ETD will apply BS7910 and FITNET (R6) defect assessment procedures for buried
(embedded) elliptical crack in bore cob to prepare the analytical solutions which will be
integrated to the software.
iv) Surface semi elliptical crack at bolthole
Fig. 5: Schematic of surface flaw at bolthole
ETD will apply BS7910 and FITNET (R6) defect assessment procedures for surface semi-
elliptical crack at bolthole to prepare the analytical solutions which will be integrated into the
software.
6. PROJECT BENEFITS
Understanding of defect assessment process and procedure is important for the engineers when
designing/ modifying, installing or assessing in-service components. Use of different defect
8
assessment procedures means spending longer time and carrying out laborious work and
creating solutions of many pages of spreadsheets (an example is shown in Figure 6).
Fig. 6: Example of manual calculation for defect assessment
‘CrackFit’:
Is able to assess cracks in both the low and high temperature components.
Covers a range of common component and crack geometries.
Various defect assessment codes such as SINTAP, BS7910, RCC-MR A16 can be used
in conjunction with this tool.
Is user-friendly for industry engineers who would like to carry out defect assessment
without going through different established codes or assessment practices.
Contains power plant ‘cycling’ and ‘sensitivity analysis’ modules.
Is flexible and can add new geometries for assessment.
The software is accompanied with a ‘Help’ manual that covers the Procedure in detail. Both for
the experienced and the younger engineers this manual can be a very useful tool for cross
reference, for calculation and analysis and it also makes an excellent learning tool. The
9
software allows an organisation to train its staff in defect assessment - from defining a specific
geometry problem to building and validating the solutions.
Although the existing CrackFit is an excellent and very fast tool for the deterministic and
probabilistic assessment of cracks in a power plant boiler/HRSG and processing plant etc.
pressure components and piping, the addition of crack assessment solutions for turbines will be
an added advantage and benefit to the operators of power generation utilities.
Another significant advantage of CrackFit is that the calculations which used to take a week,
for example, can now be performed in half a day, thus saving valuable time and costs in terms
of early component run, repair or replacement decisions. The financial benefits in terms of
reducing the lost production can run into millions per outage.
7. TIMESCALE & DELIVERABLES
The project in regards to the further development of ‘CrackFit’ to include new geometries
proposed above, will be carried out over an estimated period of up to six months. It is
envisaged that the project will start by late 2017 or at the start of 2018 and will be completed
within six months of the starting date.
Project sponsorship/ participation is open to all, although ETD reserves the right to decline an
offer of participation. ETD aims to secure sponsors now, for the initiation of the project,
which will be on the first come first serve basis.
The principal deliverable will be the ‘CrackFit software expanded version’ and one year
technical support from the date that the software is delivered. At the end of project Month 6,
the software will be delivered to the project sponsors.
A Progress Report will be issued at the end of month 3 which will be in pdf format stating the
status of completed and remaining work.
8. PRICE ESTIMATE AND CONDITIONS
In an ETD’s GSP working model ETD is solely responsible for the execution and completion
of work and delivery of the final product. Project international sponsors may contribute their
data/ experience (if necessary) on voluntary basis for the mutual benefit of the project
sponsors. In a GSP the project costs are shared between several sponsors, where each sponsor
only pays a fraction of the total cost, but receives the full project output. ETD has
successfully delivered many such projects in the past – see Appendices 2 to 4 and ETD’s
website: www.etd-consulting.com
10
Different cost categories have been set for:
a) Reduced cost for the existing sponsors (who have already purchased CrackFit for
boilers/ pressure vessels and standard laboratory fracture mechanics specimens) for
the updated and expanded software containing the boilers/PVs, lab. specimens and
turbine components.
b) Standard cost for the new sponsors (who have not previously purchased CrackFit) for
the expanded software containing the boilers/PVs, lab. specimens and turbine
components.
Other Sponsorship/ Purchase Options:
1) The existing CrackFit for the boilers/ pressure vessels and standard laboratory fracture
mechanics specimens is available for purchase by the new clients interested only in
these features and not in the turbine components.
2) There is also an option of sponsoring only the Turbine part of the work, at a lower
cost, for those not interested in the boiler/ pressure vessel crack assessment.
3) ETD has also prepared a shorter version of CrackFit for the more common crack
assessment in straight pipes only which can be purchased by the new clients at a much
reduced cost.
Materials Database:
As stated earlier, a unique benefit of CrackFit is that it can be purchased with a large materials
database for crack growth in a number of materials (as shown in Appendix 1) for high
temperature plant operating under creep and fatigue conditions. This database can be delivered
in Excel format, if required, at an additional cost, as a part of the above software or as a
separate entity.
Cost details for all of the above options will be sent upon request from the interested
sponsors/ clients.
9. ETD’s TEAM FOR THIS PROJECT
An expert team with an in-depth knowledge of power plants and understanding of defect
assessment procedures will be engaged in this project.
10. FURTHER CONTACTS
Should you require further information, please contact:
Dr Ahmed Shibli [email protected] Tel: +44 1372 363111
11
APPENDIX 1: ETD Materials Database
The list of materials which are included in ETD Materials database for crack assessment
(CrackFit) is presented below:
Grade Type of Steel
C
Carbon Steel
C Semi and Si Killed*
C Si and Al killed*
C-Mn*
0.3Mo*
Cr-Mo
Cr-Mo
1¼Cr-Mo*
0.4%C-1¼Cr-Mo*
Cr-Mo-V
½Cr-½Mo-¼V*
½Cr-Mo-V
1Cr-1Mo-¼V (forged)*
1Cr-1Mo-¼V (cast)*
1Cr-Mo-V (forged)
1Cr-Mo-V (cast)
Cr-Mo-V+ 0.4%C-1¼Cr-Mo-V
Cr-Mo-V-Ti-B
P1 C-½Mo*
P9 9Cr-1Mo*
P11 1¼Cr-½Mo
P12 1Cr-½Mo
P22 2¼Cr-1Mo
P91 9Cr-1Mo-V
P91 Mod 9Cr (IC-HAZ)
P92 12Cr-1Mo-V**
P92 12Cr-Mo-V (UTS 690-840 MPa)**
E911 9Cr-1Mo-1W-Cb
304 SS Type 304 Stainless steel
304 SS AISI type 304 and 304H
304 N SS 18Cr-8Ni-N
310 SS Type 310
310 SS 25Cr-20Ni
316 SS
316 Stainless steel
316 L(N) Stainless steel
316 L Stainless steel
316 H Stainless steel
316 H SS 316H (wrought) (inc HAZ)
316 LN 18Cr-12Ni-Mo-N
321 SS Type 321H
12
Grade Type of Steel
Type 321 (wrought) inc HAZ and ageing
18Cr-10Ni-Ti*
347 SS Type 347*
Alloy 800 Alloy 800**
800H Alloy 800H*
800HT Alloy 800HT*
800 HSS Alloy 800H
Ess1250 Esshete 1250*
Al Aluminium alloy RR 58
Aluminium alloy 2519 - T851
939 Alloy 939*
Cr-Ni
18Cr-12Ni-Mo*
18Cr-12Ni-Mo-B*
18Cr-12Ni-Nb*
18Cr-10Ni-Nb-N*
15Cr-10Ni-6Mn-Nb-V*
SS Austenitic steels
Ferritic Ferritic steels in marine environments
* constants for creep rupture equations (power law/ log power law) only
** constants for creep strain rate law only
13
APPENDIX 2: ETD’S PROFILE
ETD Consulting is an independent company registered in England. It is an engineering and
consulting company whose expertise includes life extension and integrity assessment of power
plant (conventional steam, CCGT, HRSG, Cogen, etc.) and other industrial plant (such as waste
incineration, petrochemical, off-shore structures, etc). Engineering services, consulting, R&D
and other technical projects are undertaken for individual organisations and power plants,
government bodies (such the Department of Trade and Industry, UK) and international bodies
(such as the European Commission). ETD provides consulting services to industry worldwide
and in specific to industry in the UK, Europe, North America, Japan, Middle East and Far East.
ETD’s list of clients is very large but notably has included in the past companies such as
Kyushu Electric (Japan), CLP (Hong Kong), Electricity Supply Board (Ireland), Eskom (South
Africa), Progress Energy (Florida, USA), Bharat Heavy Electrical (India), Electricite de France,
ENGIE, utilities in Germany, Pakistan, Belgium, Saudi Arabia, Bahrain, Thailand, Abu Dhabi,
Dubai, Italy, Malaysia, Indonesia, Singapore, Canada and so on.
ETD has carried out consultancy work for a large number of power and petrochemical plants
over many years, and thus ETD staff have extensive experience with long and short term
performance evaluation of power and petrochemical plant, particularly with issues/problems
related to component failure, life assessment, fitness-for-service assessment and probabilistic
lifing. Typical examples of projects carried out for power and petrochemical plants include:
Investigation of Pitting Damage to Compressor Vanes of GT11 and GT22 13E2 Gas
Turbines for Power Plants in Malaysia; Compressor blades failure analysis for a plant in
UAE. ETD RCA analysis has found that the GT compressor corrosion resulted from
moisture containing salts and acids collecting on the blading.
Failure Investigation and Root Cause Analysis (RCA) of Gas Turbine for an Integrated
Gas Development plant in Asia. ETD analysis found that black colour deposits were
adhered to the aerofoil surfaces of all four compressor blades – EDX analysis showed
significant amounts of oxygen, carbon, and presence of (highly corrosive) sulphur,
possibly as a result of ingested lube-oil and sulphur dioxide (product of fossil fuel
combustion / process fumes).
ETD is currently working on a multi-client or Group Sponsored Project (GSP) preparing
guidelines for: ‘Protection and Preservation of Power Plant Gas Turbine Compressors’,
ETD Project no: 1471-gsp-proj16.
Regular provision of failure analysis services to power and petrochemical plants in the
UK, Europe, North America, Asia, Far East, Middle East.
Life assessment of two branch welds on the hot reheat header of a coal-fired power plant
located in Malaysia. ETD undertook replication of all four cardinal positions of the two
14
branch welds, together with hardness testing. The replicas were studied and
recommendations for appropriate inspection intervals made.
Provided FFS consultancy to INEOS oil refinery in Grangemouth, Scotland. INEOS
identified a crack defect in a critical plant component (Hydrocracker), which had grown
during service. ETD undertook API 579 Level 3 FFS assessment which concluded the
crack extension was driven by cyclic stress induced fatigue, although the defect was found
to be stable. Recommendations were provided for continued in-service operation,
regarding monitoring, inspection interval/ technique, and component design modification.
Probabilistic stress analysis and life assessment for power and petroleum/petrochemical
plants in Europe and Middle East.
Integrity and Life extension study including creep and fatigue life assessment of main
steam line piping and common header system for 12 power generating units in the Saudi
Arabia (2010 – 2013).
Development of a crack assessment tool (known as ‘CrackFit’) for deterministic and
probabilistic crack assessment in high temperature components.
Reliability studies, including creep/ fatigue life assessments, of critical HRSG
components for power generating units (operating in cyclic mode) belonging to utilities in
the Middle East (2003, 2005).
Provision of specialist materials and corrosion consultancy services to Mott-MacDonald
Ltd, which involved examination of turbine bypass valve weld failures in two plants
located in the UAE (2008).
Root cause failure investigations, including thermal-mechanical fatigue failures in
superheaters/ reheaters and economisers – carried out for power and petrochemical plants
in the UK, Europe, Middle East and in the Far East.
Development of a large (1160 page) and comprehensive state-of-the-art Lifing Procedure
and associated software (known as ‘e-Lifing’) – specially developed for the assessment of
conventional power plant components, as well as HRSGs in combined cycle plants. The
project was funded by international industry stakeholders, including: Eskom (South
Africa), TransAlta (Canada and Australia), Electrabel (Belgium), and E.ON (Germany).
ETD also leads and runs a number of collaborative and international industry-supported study
programmes known as Group Sponsored Projects (GSPs). Recent examples include:
- Preservation Guidelines for CCGT & Conventional Power Plant during Short- and Long-
Term Shutdowns (2013)
- Development of Inspection, Monitoring & Life Assessment Techniques & Guidelines for
welded P91-P92 in-service Components (Continue)
- Procedure and Guidelines for the assessment of HRSG safe remaining life (2015)
15
- Damage to Power Plant Due to Cyclic Operation – Operational, Technical & Cost Issues
(2002 and 2009).
- Damage to CCGTs Due to Cyclic Operation – Operational, Technical & Cost Issues
(2003 and 2010).
- Survey of Advanced Inspection Techniques for Plants & Recommendations for Best
Practices (2008)
- Survey of On-Line Monitoring Techniques for Plants & Recommendations for Best
Practices (2007)
- Guidelines for Inspection, Maintenance, Monitoring and Repair of HRSGs (2006).
As ETD carries out both plant services/ consulting and international industry collaborative
R&D projects, the company can draw on the expertise of its R&D staff to provide best advice
and innovative solutions to industrial problems when providing plant services consultancy.
Further details may be found at the company website: www.etd-consulting.com
16
APPENDIX 3: ETD’s STAFF & EXPERTISE
ETD’s staff and dedicated consultants (listed below) include experts in both GT and ST,
boiler and HRSG plant performance modelling (reliability), operation and maintenance,
defect assessment, plant and component design and life assessment, materials and welding
issues, corrosion and water chemistry. This experience gives the company a broad
understanding of the potential damage mechanisms and at-risk areas in conventional boiler
and CCGT/ HRSG plant under various operating conditions. Apart from the knowledgebase of
these staff and consultant’s ETD has good links with plant designers and manufacturers and
can thus draw on their experience when needed. Indeed, some of the staff of these design
and manufacturing organisations and the plant operators regularly lecture at the ETD
organised training courses on power plants in particular the components’ defect assessment
procedures, codes & standards, plant technical & cost performance, life assessment &
extension, cyclic capability study etc.
The profile of some of the ETD technical staff and consultants is provided below to show its
background in power plant boiler and HRSG issues.
Dr David Robertson: Dr Robertson gained his qualifications in metallurgy and materials at
Imperial College, University of London. He has over fifteen years’ experience of materials
used in the power, petrochemical, defence and aerospace industries. At ETD Dr Robertson
has been working on projects related to high temperature plant integrity, materials and
welding, and maintenance issues. Dr Robertson also has experience in the investigation of in-
service failures and manufacturing defects (in steels and non-ferrous alloys). Recently, he
has performed root cause analysis of failures in HRSG tubes/welds (superheater/ reheater,
economiser and evaporator), turbine bypass valves and superheater drain components. Dr
Robertson co-ordinated ETD’s group-sponsored project on Cyclic Operation of CCGTs, and
also led an ETD project on the development of a new state-of-the-art Lifing Procedure for
boilers (including HRSGs), turbines, electrical components and auxiliary equipment. Prior
to joining ETD, Dr Robertson worked for eight years in the Plant Integrity Department at
another plant life assessment service provider in the UK. He has delivered courses on
HRSG maintenance in London, Malaysia and Canada.
Dr Sarinova Simandjuntak: Dr Simandjuntak gained her qualifications in metallurgy and
materials, and corrosion engineering, at Imperial College, London. Dr Simandjuntak has
extensive experience in materials and mechanical engineering aspects of high temperature plant
and is one of ETD’s well recognized consultants (previously ETD’s full-time employee) in
defect assessment, Risk Based Inspection and Maintenance (RBMI), on-line monitoring of
power plants, FE analysis, probabilistic assessment, life assessment and component stress
analysis in general. Dr Simandjuntak was involved in the development of ETD’s procedures &
software for crack assessment for high temperature plant components, and also contributed to
the development of ETD’s new Remaining Life Assessment Procedure for boilers and turbines,
which will incorporate both deterministic and probabilistic life assessment. She was involved in
ETD’s risk based maintenance (RBM) study for a waste-to-energy power plant in the UK. She
was involved in developing ETD’s RBM procedure called ‘Riskfit’ and has led ETD’s power
company ‘workers’ and ‘management’ workshops on risk management in their plant. Dr
Simandjuntak has also been involved and indeed led some of the European power utilities’
projects in enterprise-wise risk studies.
Dr James Pullen: James gained his Doctorate from the University of Brighton and he also
holds a Masters degree in Mechanical Engineering from the University of Sheffield. Prior to
17
joining ETD as a project engineer, he worked for E.ON UK. AT ETD, Dr Pullen has been
involved in defect assessment using ETD’s Crackfit software, component failure analysis and
life assessment projects (e.g. for P91 and T91), piping system stress analysis using Caesar II, as
well as various Remaining Life Assessment, asset management/ improvement projects. At
E.ON, Dr Pullen worked on asset management and consultancy projects related to engineering
of gas turbine combustion systems, emissions control, legislative compliance, and fuel quality
issues. He performed routine condition monitoring of GE 9FA gas turbines, and completed a
secondment at Connah’s Quay Power Station (1420MW CCGT, with 3x GE 9FAs), where he
completed efficiency improvement studies, evaluating technology upgrades to the inlet air
filtration system and the compressor wash systems, which involved costs versus benefits
analysis.
Ms F Akther: Ms Akther gained her qualifications in metallurgy and materials and has
completed her master’s degree at Queen Mary, University of London. At ETD, she has been
working on defect assessment, life assessment, condition assessment, risk based maintenance &
inspection, fitness for service assessment and root cause failure analysis of power plant
components. She has completed several projects which were involved in performing detailed
plant survey, critical data review, analysis and preparation of report including
recommendations. Recently she has completed a project in component defect assessment using
ETD’s Crackfit software for a power plant in Asia. She is also involved in some of ETD’s
international industry funded projects related to defect assessment, plant integrity and condition
assessment. She was involved in the development of ETD’s project ‘eAtlas - A compendium of
replicas and microstructures for life estimation of Ageing Power and Petrochemical Plant’. She
has also worked on cycling power plant technical and costs issues and RBM study of power
plant components etc.
Mr Tony Callagy: A Chartered and a Euro Engineer, Mr Callagy has 25 years of experience
with the Electricity Supply Board of Ireland both in the conventional plant and with the
CCGTs. His most recent experience was working as a Business Manager carrying out studies
on the refurbishment/ repowering requirements of aging power stations coupled with the cost
benefit analysis of upgrading and uprating. He further has worked in failure analysis of
mechanical plant and in design improvements. In addition, he has been involved in the
designing of the water/ steam cycle for new CHPs to replace an existing power station. Mr
Callagy has been responsible for the mechanical integrity of the company’s power generation
equipment, including steam lines and turbines, failure analysis of mechanical plant and
design improvements of plants in the USA, Turkey and Pakistan.
18
APPENDIX 4: ETD’S EXPERIENCE AND CAPABILITY
The following provide information about some of the projects that ETD has carried out in the
field of defect assessment, power plant performance and cost analysis, as well as life
assessment & extension. A number of different projects are shown as examples of ETD’s
diverse experience in power plant and related areas and ETD’s leadership in the field of power
plant technical performance.
Provide Analytical Software, Laboratory Services, Consultation, Training on Creep Crack
Growth Testing, Data Analysis and Defect Assessment [ETD Project No: 1403-tp-proj15]
This project has been completed for a client in Malaysia in 2015. The project aim was to
provide consultation and training to client’s staff and providing appropriate tools (analytical
software, literature, data etc) with the objective of developing capabilities in the prediction of
Creep Crack Growth initiation and growth in boiler components especially in P91 welded
joints. Creep crack growth testing for P91 samples was performed for the prediction of crack
growth initiation and growth. As a part of the project, the client has also purchased ETD’s
Crackfit software with boiler components. Appropriate training on use of Crackfit software and
the defect assessment procedures was provided to the client’s selected staff.
Creep Rupture Strength of ‘Abnormal P91’ Materials and Welds [ETD project no: 1338-
gsp-proj14]
This is a Group Sponsored Project (GSP) ETD has started recently for its various sponsors.
Many utilities and plants have been discovering ‘abnormal’ (or ‘aberrant’) P91 base metal and
welded joints in their plants. Although it is now well known that heat treatment is critical in
achieving full strength in high Cr martensitic steels, it is clear that for various reasons many
materials suppliers, manufacturers or welding companies have failed to realize this criticality.
As a result, there is a worldwide problem with P9 1 base metals and/or whole welded joints that
have not been heat treated to specifications and/or best practices, resulting in hardness below
the acceptable limit and/or the microstructure is not in the correct, fully martensitic condition.
There is an urgent need to obtain creep rupture data that can be used to estimate the long-term
strength of abnormal P91 materials and welds found in plant. There could be considerable
variation in the strength level of different materials/welds as a result of the different ways in
which heat treatment of base metal and/or welds may deviate from specification requirements.
The objective of this project is to carry out stress rupture testing of abnormal P91 base metals
and welds, which have been incorrectly heat-treated to produce a number of abnormal
conditions (over-tempered, etc).
Development of Inspection, Monitoring and Life Assessment Technologies & Guidelines
for P91 & P92 In-service Components [ETD Project No: 1265-gsp-proj13]
This about to be completed multi-client Group Sponsored Project (GSP) is of three years
duration and involved development of new inspection and monitoring techniques for detecting
early stage creep cavitation damage in P91 and P92 type martensitic steel components and
pressure vessels. The techniques studied were magnetic resonance and resistance of in-service
components and change in these values with the evolution of creep damage;
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Impact of Cyclic Operation on Maintenance Programs [ETD project no: 1348-tp-prop14]
Maintenance strategy is crucial to the safe, reliable and economic performance of all types of
high temperature plants operating under cycling regime. Identification of appropriate
methodologies for assessing the impact of change in operating mode (from base load to
cyclic), is essential, to provide the basis for optimization of inspection and maintenance
programs and to identify modifications that are required to the existing programs. This study
identified modifications to maintenance programs that address the consequences of cyclic
operation – on plant equipment performance and its asset management.
Reliability and performance issues with Combustion Turbines [ETD project no: 1349-tp-
prop14]
This project identified operational issues with combustion turbines (both simple cycle and
combined cycle), by completing a survey of the most prominent reliability and performance
problems, and ways to address them. ETD evaluated the prominence of technical issues that
impact the performance of combustion turbines, under varying operating conditions (base
load, cyclic operation and rapid start-ups). The work identified specific performance issues,
their causes and appropriate resolutions.
Benchmarking of Conventional Power & Gas Turbine Plants [ETD project no: 1186-gsp-
proj11]
This project involved in the assessment of Technical and Cost performance for utilities in
North America, Europe, Australasia and Asia. This study dealt with analysis of the power
plant performance using benchmarking techniques. The number of plants included in ETD’s
database was ~ 100 plants consisting of 39% of conventional power plants, 37% of combined
cycle gas turbines, 16% of cogeneration and 8% of open cycle gas turbine. The analysis was
performed for gas turbines, steam turbines, boilers & HRSGs, generators etc. The performance
in terms of production, financial cost and O&M strategies were analysed and compared to peer
groups. This was an ongoing project since 2010; a second project started in Jan 2011
exclusively for a European utility comprising of 11 power plants with different GT frames
such as Siemens, General Electric and Alstom machines.
Impact of Cycling/ Two Shift Damage on the O&M Cost and Reliability of Natural Gas-
Fired Combined Cycle (NGCC) Power Plants [ETD project no: 1228-tp-proj12]
The objective of this project, conducted for the North American Thermal Generation Interest
Group, was to determine the economic/ cost and reliability impact of increasing number of load
cycles and two shift operations on NGCC (CCGT) power plants caused by the increasing
penetration of non-dispatchable renewable, like solar, hydro and wind generators, and other
factors. Another objective was to provide guidance on methods to reduce the impact of cycling
on damage accumulation in major components.
Impact of Cycling on the Operation and Maintenance Cost of Conventional and Combined
Cycle Power Plant [ETD project no: 1229-tp-proj12]
The objective of this project, conducted for American and European utilities, was to create
awareness in the project members about the effect of plant cycling on the Operation &
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Maintenance (O&M) cost due to increased damage, related inspection, repair, maintenance,
plant modification etc. Furthermore, the project also discussed the requirement of increased
plant cycling due to future introduction of renewable energy source. The study also provided
guidance on methods to reduce the impact of cycling on damage accumulation in major
components of conventional and CCGT plants.
Cogeneration Plant Performance Assessment using Benchmarking Approach [ETD project
no: 1109-gsp-proj09]
The project involved in assessment of operational and maintenance performance of
cogeneration plants using benchmarking approach. Twelve plants located in America, Canada,
France, The Netherlands and Spain was included in this study. The ETD database of
worldwide plant operational and maintenance (O&M) performance including cost was used to
benchmark the participated plants. The data were selected from units with similarities to
cogen plants (known as the peer group) with respect to the type/size of Gas Turbine (GT)
frame, type of Steam Generator (e.g. HRSG), type of operation, size/ capacity, and age.
This included performance data from over 100 units of similar GT frames and Steam
Generators and over 30 Cogen plants (excluding projects’ participated plants). The O&M
performance such as lifetime generation, availability, outages and finance of individual plant
were assessed and compared amongst the participated plants and also against the
performance of the selected units from the ETD database.
Database of Conventional Power and Gas Turbine Plants – Technical & Cost Analysis
[ETD project no: 1109-gsp-proj08]
This study involved in the analysis of 43 conventional, 38 combined cycle, 20 open-cycle and
2 combined heat and power plants. The project was carried out for one of the largest European
utility. The main objective of this study was to analyse the overall plant performance focusing
the generation level, operation issues (including damage and consequent component repair or
replacement), maintenance, inspection, financial investment etc.
Replacement of Components in Aging Power Plant Boilers & HRSGs – Technical and
Material Issues [ETD project no: 1107-gsp-proj10]
The project dealt with Technical and Material Issues involving utilities from North
America and Europe. The study involved in analysing various materials, components design,
replacement strategies and impact on the plant overall performance. The power plants
involved in this study were of different output capacities and ages (2011).
Boiler Tube Failure Prevention & Management [ETD project no: 1230-gsp-proj12]
The objective of this ETD group sponsored project was to provide participants/sponsors with
practical guidelines for boiler tube failure prevention including examples of case studies of
boiler tube failures from a number of worldwide power plants. Typical questions were
prepared by ETD experts to collect all relevant information. These typical questions were
illustrative of questions with similar format that may be asked for this project. The Risk Based
Inspection (RBI) approach has also been introduced to predict the lifetime of tubes for the case
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when tube failures will not lead to catastrophic or fatal consequence to the integrity and safety
of the structure/plant.
CCGT/HRSG Cyclic Operation Capability Studies for Prai Power Plant, Malaysia [ETD
project no: 1142-tp-proj10-a]
ETD has performed cyclic operation capability study for Prai Power Plant (PPSB) in 2010.
The project objective was to carry out cyclic operations capability studies for the PPSB Power
Plant. The study involved in analysing overall CCGT plant design issues and HRSG design
issues, and the capability to operate with (daily) load swings between the minimum load of
210 MW and base load of 350 MW, and with specified numbers of hot/warm/cold starts per
year. This study has been performed in order to evaluate the possible consequences of cyclic
operation at PPSB power plant and its effect on the life-time of critical HRSG components
involving measurement, interpretation and analysis of heat rate readings collected during plant
operation by thermocouples installed in specific locations advised by ETD and DCS data.
Risk Based Management (RBM) Study for London Waste’s Power Generating unit [ETD
project no: 1119-tp-proj09]
This project involved in carrying out a Risk Based Management (RBM) study on the boiler
units and one control system for London Waste Limited (LWL), the UK’s largest plant
generating power from waste. The main objective of the study was to undertake the risk based
management study for the selected critical components by implementation of ETD’s RBMI
procedure ‘RiskFit’. The study involved identification and management of risk in order to
ensure safe operation, as well as optimized maintenance and inspection activities, whilst not
affecting plant availability and/or personnel safety.
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