DEKRA Material Testing & Inspection COMMITTED TO SAFETY Asset Integrity & Arthur Stam Non Destructive Testing Veolia 16-6-2017
Our descent: KEMA Founded in 1927 in The Netherlands Testing institute for electro-technical materials Institute for electricity generation, distribution and electrical product testing KEMA designed and built their own type of nuclear reactor in the 1970 s (KSTR, KEMA Suspension Test Reactor) Product testing and certificationn sold to DEKRA in 2009. AIM and NDT sold to DEKRA in 2014. Slide 2 2014 DEKRA Material Testing & Inspection
Succesful integrations Service Unit Material Testing & Inspection 2008 2009 2010 2011 2012 2013 2014 Inspection NDT/DT Finland Sweden Czech Republic Lithuania Turkey Kazakhstan Azerbaijan Czech Republic Germany South Africa PI & ANDT Netherlands Germany Germany Germany Slide 3 2014 DEKRA Material Testing & Inspection
Mission statement As independent company, DEKRA Solutions provides services to support asset managers in operating and maintaining their assets. We significantly improve asset reliability, availability, safety and reduce costs. Our services are based on deep technical knowledge, longstanding experience integrated with advanced NDT services. Slide 4 2014 DEKRA Material Testing & Inspection
Services Advanced NDT - SPICA (strain monitoring) - Generator inspections - KIRR (retaining ring) - ARGIS (EL CID, wedge tightness, visual) - Turbine inspections Asset Integrity - Risk and reliability analysis - Root cause and failure analysis - Condition and remaining life assessment - Corrosion analysis and monitoring - QA QC - Specialized UT (Phased Array, TOFD) and other services on request Slide 5 2014 DEKRA Material Testing & Inspection
Asset Integrity Management Non Destructive Testing Design Design Review Tender Process Support Reliability & Risk Assessments Failure & Root Cause Analyses Fitness for Service Analyses Mathematical Modeling Life Cycle Extension Solutions! Procurement, Manufacturing & Construction Quality Assurance / Control Procurement & Manufacturing Review Zero / As Built Reference Inspections Construction Surveillance Reliability & Risk Assessments Condition & Remaining Life Assessm. Water Treatment & Chemistry Corrosion, Slagging & Fouling Material & Welding Consultancy Operation and Maintenance Commissioning Technical Due Diligence Performance Testing Witnessing Acceptance Testing 2014 DEKRA 6
Strain [%] Strain Monitoring (SPICA) Creep is a main failure mechanism in steam lines operating at high temperature and pressure. SPICA is a robust measurement method developed for on stream strain measurement. It is based on the actual condition. The SPICA results show the strain distribution in two orthagonal directions in which both local (Heat Affected Zone in welds) as integral strain are determined. If the strain is measured on a continuos base the strain rate and, with application of criteria for strain, the life time consumption due to creep can be predicted. Accurate life prediction, allowing for extended service life, reduced plant downtime and increased production capacity. Higher safety with lower safety margins. 10 9 8 7 6 5 4 3 2 1 HAZ Base Weld Average 0 0 2000 4000 6000 8000 Exposed hours Page 7 2013 DEKRA
Generator Retaining Ring Inspections As a result of mechanical, chemical and electrical circumstances, flaw indications may appear in retaining rings. Replacing these rings involves substantial costs. Automated scanning is performed without pulling the rotor. Ultrasonic (TOFD, PE) and eddy current testing is performed. Fitness for service can be performed using finite element calculations. A retaining ring inspection using a robot (KIRR) is quickly done. It provides the condition, and trending can be done. Money is saved on rotor and retaining rings disassembly or even ring replacement. Page 8 2013 DEKRA
Generator rotor and stator inspections - ARGIS The condition of the generator and its core deteriorates over time increasing the chance on failures. To avoid unplanned outages, quantitative testing and periodic inspections are necessary to assess the condition of the generator core. Robotic testing of: Low flux leakage test (ELCID) Wedge tightness assessment Visual testing Without pulling the rotor. Less time and less costs (few days inspection in stead of 3 weeks). And: less risk on damage to the generator stator and rotor parts. A generator inspection is not on the critical path of outage anymore. Page 9 2013 DEKRA
Turbine inspections Rotor body inspections (ST, GT) GT disc inspections Rotor body testing with blades in place (ST) ETS: testing of a steam turbine housing Page 10 2013 DEKRA
Specialized UT Measurements on difficult geometries (drums, turbine blades,..) and difficult materials (copper, austenitics, Ni-alloys) Example: TOFD inspection of fillet welds in steam drums Precise registration of location in relation to inspection results allows for comparison of data in time. In the example project, inspections showed many indications of which many were attributed to grinding (both drums). Some indications may have resulted from cracking in the longitudinal direction of the drum. Page 11 2013 DEKRA
Quality Asessment & Quality Control (QA/QC) Project engineering phase: Reviewing project requirements and standards, drawings, test & inspection plans main contractors. Component manufacturing phase: Review and approval of test & inspection plans (Coordination of) inspections & verifications. Final inspections and documentation review. Construction & commissioning phase: As build reference inspections, witnessing acceptance testing, support of on-site customer inspection staff. Slide 12 2014 DEKRA Material Testing & Inspection
Reliability Improvement & Risk analysis Typical questions that are asked: How can we increase the reliability of our plant? Where should we invest now that markets have changed? What are critical components of our plant? We apply (amongst others) Failure Mode Effect & Criticality Analysis (FMECA) Failure Data of sub-systems and components (in house database) Spare parts analysis We support in decision analysis new build concepts, Capacity expansion planning, target setting, changing operational modes, maintenance, Life Time Extension. 2014 DEKRA 13
Failure and Root Cause Analysis A root cause is defined as the cause that, if corrected, would prevent a recurrence of this and similar occurrences. 30 % of the failures of many components have a repetitive character. Finding root causes and solutions are important to prevent recurrence. Kepner-Tregoe, events & causal factor charting or other methods to find root causes. DEKRA is specialized in the analysis of failures in mechanical and electrical equipment. Specialists knowledge is supported by laboratory investigations and (life time) modeling capabilities. 2014 DEKRA 14
Condition and Remaining Life Time Assessment Review of condition and remaining life time of installations & components on the basis of maintenance, inspection and damage history. How can the condition of an installation be determined (NDT, inspections) be monitored over a longer period of time Analysis on the basis of material tests (replica s), NDT, monitoring, data analysis, (code) mathematical modeling. Maximum performance of Plant during its Life Cycle by avoiding unplanned outages through timely replacement of components and equipment. 2014 DEKRA 15
Fitness for Service / Fitness for Purpose Decision procedure Run-Repair-Replace : Critical defect dimensions Residual life estimation for components with indications Leak before break or break before leak assessments Examples of components (Main) Steam Lines, Steam Headers, Steam Valves, Steam Drums, ST & GT Rotors Pulsation dampers Pressurized containers / tanks / lines NDT Defect Dimensions Material Properties Evaluation Defect Fracture Mechanics Analysis Thermo- Mechanical Stresses alternator rotor retaining rings Run Repair Replace Slide 16 2014 DEKRA Material Testing & Inspection
Condition and Remaining Life Time Assessment (example) Question from Major Steel Producer: We have 2 HP steam boilers having 200.000 hours of operation. Can the life of these boilers be extended for another 100.000 hours? From both boilers, DEKRA analyzed the operational, maintenance and damage history and the results of the inspections carried out. For every component the present condition and consumed lifetime was determined on the basis of operational conditions and design principles. DEKRA could show that an additional 100.000 hours of operational time would be no problem for both installations and that the present maintenance and inspection concept would need no severe change to keep up this technical condition. 2014 DEKRA 17
Corrosion monitoring & analysis Corrosion in boilers and other components is a well-known problem, leading to unplanned unavailability, acid emissions, etc. Analysis is done using SEM (Scanning Electron Microscopy) and thermodynamic software. Corrosion can be monitored using: passively cooled coupons (KEMCOPs) on-line corrosion measurements using Electro Chemical Noise (ECN) Advice on operations or material use to reduce corrosion provides less shut downs and less maintenance. Slide 18 2014 DEKRA Material Testing & Inspection
Corrosion monitoring & analysis (example) A high pressure drop was observed in a HRSG, along with fouling of finned pipes. Fouling was investigated with XRD and SEM. Iron sulphates were found. These are formed during operation due to very small amount of sulphur in the fuel, Due to frequent start stops, corrosion layers spall and cause fouling. Acid dew point corrosion is not a cause. Conditioning and cleaning procedures have been advised. Slide 19 2014 DEKRA Material Testing & Inspection
Gas turbine inlet fouling A gas turbine trip occurred. Particles were found on the compressor blades. It was requested to examine these particles and to investigate a possible link with the trip. ZnSO 4,((NH 4 ), ZnCl 4 and (NH 4 ) 3 ClZnCl 4 ) were found. A likely cause was winter smog, quickly fouling the filter and causing ion transport through the filter. Subsequently, acid droplets condense on ducting and react with the Zn-primer. Slide 20 2014 DEKRA Material Testing & Inspection
Concrete Asset Management DEKRA can systematically perform concrete inspections to produce instructions in order to maintain a safe design. Testing and inspection Test of chemical and physical status Condition assessment Proposing of actions / Repairing Strategy Quality and Control Management Monitoring / Quality Control Project management / inquiry evaluation
Contact: DEKRA Material testing & Inspection Meander 1051 6825 MJ Arnhem P.O. Box 5185 6802 ED Arnhem T +31 88 96 83025 mti.nl@dekra.com www.dekra-industrial.nl