ETD Technology Newsletter January 2017

New Technologies for High Temperature Plant Inspection, Repair

and Life Assessment - particularly for P91/ P92 components
Contents ETD is pleased to announce an exclusive
partnership agreement with Chugoku Electric
Updates on
Power Company (CEPCO), Japan. ETD can now
Recent Group
offer patented technologies for the inspection,
Sponsored
monitoring and life extension of high temperature
Projects (GSPs)
plant components. (references and details can be
provided on request):
Third Party 1) Technology for reinforcing seamless or seam
Failure welded pipelines, pipe bends etc. Photo: Meeting of ETD Staff with CEPCO
Analysis Management to sign collaboration agreement.
Projects The Technology is known as Obikou or Bandage
Reinforcement Technology and is offered for
reinforcing creep damaged pipelines by simply Obikou reinforced pipe bend
Third Party
and quickly winding an alloy strip at site, in order
Life
to improve the creep strength of straight, bent, or
Assessment
seam welded high temperature pipes. The
Projects
method is applicable to steel pipe including P91,
P92 and other high temperature steels. Both
ETDs 2017 R&D and plant experience has shown that
Upcoming residual life can be extended by a factor of 4.
Events

Electrical
Discharge
Sampling
Equipment
(EDSE)

Scanning Force
Microscope
(SFM)

ETDs Outage
Services 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.
 VVa

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.
==================================================================================================

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

Various flange type pipeline reinforcements 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. Contd.
 ETD Technology Newsletter January 2017
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.

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

These new developments combined with the use of ETDs 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. Contd.
 ETD Technology Newsletter January 2017
TRAINING of ETD ENGINEERS

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.
=======================================================
ETDs 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.
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
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)
 ETD Technology Newsletter January 2017
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 ETDs 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.
=========================================================================================

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.

ETDs 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.
 ETD Technology Newsletter January 2017
Examples of ETDs Recently Completed Third Party Failure Analysis Projects
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 clients 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.
ETD has extensive knowledge and experience of damage mechanisms and failure root cause analysis of systems
operating in power plants. For more information about ETDs Failure Analysis services, please click here.
 ETD Technology Newsletter January 2017
Examples of ETDs 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 clients 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 ETDs 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 clients existing unit. The clients 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 ETDs Stress Analysis services, please click here.

If you would like us to provide a quote on solving problems that may have arisen at your plant please dont
hesitate to contact us at: enquiries@etd-consulting.com
ETD Technology Newsletter January 2017
ETDs 2017 Events Diary
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

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

We also offer in-house Training Courses on a wide variety of power and process plant issues.
For more information click here.
 ETD Technology Newsletter January 2017
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 This is a picture of a boat sample that can be cut out of
accurate quantitative life assessment. your pipe. The maximum depth our electrodes can go is
20mm in depth, 20mm width and 35mm in length.
Industry Need
The most accurate way of determining an aged materials condition is through
non-destructive, physical testing. For a large plant component, this is obviously
Client Feedback
impossible without taking a sample. Without care, this sample can leave the We were pleased to be able to use the scoop sampling
component damaged with stress concentrations and a reduced wall thickness, technique on this rotor and believe there is a potential
shortening the service life. for use elsewhere. We were very pleased with the results
as we have been able to provide substantially more
The Solution information on the crack mechanism than we would
Based on the EDM process, the EDSE cuts out small, thin section of samples; have been able to do with surface metallography.
leaving no sharp corners and without inflicting work hardening on the
component surface. These samples can then be machined down to be used in Feedback from a European Turbine Manufacturer - for
creep, fatigue, tensile, toughness and hardness tests. The EDSE can cut out small work on their steam turbine rotor. This involved cutting
out samples up to 20 mm thick to investigate the root
slices between 1 to 20 mm thick and approximately 20mm2 or 40mm2 or 40mm
cause of crack initiation and propagation
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.

EDSE is available for purchase or as part of ETDs inspection services. For

further details or to request a demonstration please contact us.
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.
 ETD Technology Newsletter January 2017
Scanning Force Microscope (SFM)
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 !
A revolution in non-destructive on-site examination and Advantages Over Current Tools
testing of industrial components and materials for nano or SFM has the following significant advantages over
micro level defects, microstructural deterioration and other the other NDT and diagnostic tools currently in use:
microstructural properties.
SFM can be used on-site and attached directly to
the component being investigated after polishing the
The image on the right shows area under study to 1 micron level (same as for
the microscope scanning head replication) and etching.
(square box in the centre)
mounted on a mobile frame that The ability to view defects in 3D at the nanometer
sits on a fixed frame which in scale (with sizes of the order of 0.01-0.1 microns)
turn is attached to the allows for early-stage damage detection that would
component under investigation. 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
What is I-SFM? be missed by most NDE techniques.
SFM images
SFM or I-SFM is a portable acquired before
version of the Atomic Force (top) and after
Microscope that has been chemical
developed for on-site etching of a P91
damage and microstructural sample, sowing
imaging of critical creep cavities.
components in industry or
other large structures
metallic or non-metallic.
Three dimensional image a creep cavity
SFM mounted on a pipe. This video shows
Once mounted the SFM the microscope
movement and scanning is mounted on a
controlled by a laptop mobile frame that
which displays and stores sits on a fixed
the material defect and frame which in
microstructural images/ turn is attached to
features. the component
under
investigation.
(Continued on next page)
 ETD Technology Newsletter January 2017
Latest Scanning Force Microscope (SFM) News (Contd.)
SFM is now in the Group Sponsored Project P91-P92 Inspection and Life assessment. It is another one of ETDs
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.

7
80 nm
100 nm
120 nm
6
Top two photos: Tests being
5 performed on circumferential and
seam welded P91 and P92 pipes.
4
um3

Bottom Figure: Volume fraction

2
of cavities versus life consumption
1
as shown using the SFM on the
above test pipes.
0
0 1000 2000 3000 4000 5000 6000 7000 8000
Time (Hours)

SFM is available for purchase or as part of ETDs inspection services. For further details please contact us.
 ETD Technology Newsletter 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