Integrity NDT Power Plant Presentation PDF

INTEGRITY NDT
POWER STATION INSPECTION

MANAGEMENT SERVICES
www.integrityndt.com.tr www.integrityndt.com
Ivedik Org. San. Böl. Melih Gökçek Bulvarı, Eminel İş Merkezi No:18/94 YENIMAHALLE/ANKARA/TURKEY
Tel: +903123944331 Fax: +903123944332 Tax No: 4650360303
Company Profile
Integrity NDT Ltd was formed in in the UK in 2004 to provide NDT services, Inspection
Management services, and Asset Management Software to fabrication, power and
process plant engineers.
Integrity NDT Engineering Turkey formed in Ankara in 2009 by Integrity NDT Europe
Team to provide NDT services throughout Turkey.
Integrity NDT through our extensive experience of Non-Destructive Testing across

industry, we deliver a wide range of services and software support to ensure the cost
effective quality assessment of power, process, and chemical plant around the world.
Integrity NDT Engineering Turkey formed in Ankara in 2009 by Integrity
NDT Europe Team to provide NDT services throughout Turkey
Internationally recognised accreditation
Since formation in 2004, Integrity NDT Ltd. has achieved
ISO:9001 accreditation and become a key service
provider and approved supplier to the likes of British
Energy and International Power, GDF Suez…and others..
We deliver powerful and cost effective asset and
inspection management and inspection software
solutions, we have a wealth of experience in planning
and carrying out all aspects of NDT in fabrication, power,
and process plant worldwide.
Integrity NDT Turkey – Accreditation and Qualification
We have achieved ISO 9001 accreditation in Turkey, currently working towards
EN/ISO : 17020 Independent Inspection Company accreditation
NDT Qualifications
Integrity NDT Engineering staff have a suite of independent inspection
qualifications conforming to EN 473 (PCN) and ISO 9712 standards Levels II and III
in all major and advanced NDT methods
Non-Destructive Testing Services
NDT is integral to both construction and in-service plant life assessment tasks, providing raw data
to the fracture mechanics sciences and assuring the integrity of equipment and fabrications to
clients, regulatory and insurance bodies alike.
Integrity NDT have many years of experience in frontline NDT activities across all industry sectors,
planning and managing shutdown or ‘turn around’ activities, and consultancy on appropriate
techniques to target particular defects or plant issues.
INSPECTION
ADVANCED AUT AUT SCANNER
PLANT OUTAGE MANAGEMENT RESEARCH AND
INSPECTION DESIGN &
MANAGEMENT SOFTWARE DEVELOPMENT
APPLICATIONS PRODUCTION
DEVELOPEMENT
NDT Services
Integrity NDT Engineering conventional NDT Services:

• Visual Inspection
• Penetrant Inspection
• Magnetic Particle Inspection
• Conventional Manual Ultrasonic Inspection
• Eddy Current Inspection (Surface and Tube inspection)
Integrity NDT Engineering advanced NDT Services:

• Time of Flight Diffraction (TOFD) Inspection
• Phased Array (PA) Ultrasonic Inspection
• Corrosion Mapping
• EMAT
• Oxide Thickness Measurement
• Material Analysis
• Metallurgical Services
• Hardness Testing
Field Application – Experience and References
Our experiences and references cover a range of industrial sectors
• Power Plant inspection
• Refinery inspection
• Storage Tank inspection
• Manufacturing sector inspections
Power Station Applications and Outage
Management – Our background
CCGT Power Plant Inspection Management Services

Integrity NDT provide NDT Service including Outage Management at the following
sites:-
Deeside Power (GDF Suez) Alstom 13E2 498MW
Marmara Ereglisi (GDF Suez) Alstom 13E2 480MW
Baymina Elektrik (GDF Suez) (Ankara) GE 9FA 770MW
Pelican Point (South Australia) (GDF Suez) ALSTOM 13E2 487MW
Swanbank E (South East Queensland Australia) (Stanwell Corp) Alstom GT26 385MW
Trakya Elektrik AŞ. (Marmara Ereğlisi) Siemens – 478 MW
Fossil fuel
Hub River (Karachi Pakistan) (GDF Suez) Oil fired 4x323MW
CENAL Power Plant Construction Project – 1320MW
INSPECTION MANAGEMENT
OUTAGE PREPARATION
MANAGING WORKSCOPE (SIMD)
INSPECTION
REPORTING
OUTAGE PREPARATIONS
• Workscope and timescale preparation with Station Engineering
• Pre-planning; access and preparation requirements with Station Engineering
• Creating Site Team
• Uploading the workscope to Integrity Site Inspection Management Database

(SIMD)
INTEGRITY NDT SITE TEAM STRUCTURE
Supervisor NDT Level III
Assistant Supervisor NDT

Level II
Technical Clerk
Inspection Technicians
MANAGING WORKSCOPE (SIMD)
SITE INSPECTION MANAGEMENT DATABASE
1. Uploading the Planned Workscope into SIMD

2. Daily Outage ‘Morning meetings’ – Station Engineering/Alstom GT Engineering
Team/Integrity NDT; Outage daily coordination..
3. Generating Work Request via SIMD for each individual inspections
4. Provide all information to the inspection technician (TECHNICIAN TASK PACK)
TASK PACK Includes :

NDT Work Request;
Component identification,
unique reporting number,
task instruction, drawing(s)
and any related previous
inspection history
5. Carrying out Inspection
All results and related information (photos,

drawing, etc..) compiled into the task pack
by the inspection technician.
6. Reporting
• Task Pack and all related inspection result detaıls to Technical Clerk
• Informatıon compiled and entered into SIMD
• Electronic Inspection Report is created vıa SIMD
• Report to Supervisor for review and Level 3 approval
• Report filed to site final NDT report folder
TASK PACK SIMD INSPECTION SUPERVISOR

REPORT REVIEW
FINAL REPORT
SIMD ‘Our approach to controlling outage workflow’
1. Workscope upload to SIMD

Grouped plant area inspection activities / STATUS
2. Live inspection activity STATUS , search and output report
3. Inspection findings and ‘’ REFER STATION ‘’ tracking / reporting
4. Emergent work additions and tracking / STATUS with MANHOURS
5. Outage summary reporting and final SIMD STATUS tracking completition

Outage Inspection Reporting - Plant Areas
• TURBINE (GT & ST ) AND GENERATORS
• HRSG
• BALANCE OF PLANT
• MAIN STEAM
Main Steam Pipework Inspection Management
Our approach to Main Steam Pipework inspection has been generated primarily in response to
Plant Operation and ‘Engineering departments’ technical procedure releases, and it is of
particular relevance to engineers responsible for HRSG linked P22 and P91 main steam systems
that are close to (or have reached) the operational hours where commencement of a pipe system
inspection program is necessary
• Inspection Assessment, Planning and Management
• Automated Ultrasonic Weld Inspections (TOFD/Phased Array)
• Standard MPI / UT inspections
• Metallurgical Replication Assessment and Hardness Testing
• Diametric Creep measurements and Material Analysis
• QUARTZ ProGect Pipework Management software
P91 Pipework Iinspections
Manufacturing and O&M problems..
The well documented concerns raised regarding 9-12Cr material continue to cause issues, how to
handle these issues and the required QA inspection and monitoring is essential to asset
management.
• The lack of understanding of how the material is required to be handled, from fabrication
through to operation has caused numerous premature failures, excessive forced outages and
extensive re-works.
• The creation of the materials superior properties depend entirely on precise heat treatment
and the maintenance of the microstructure throughout its service by controlled operating
conditions.
• Incorrect PWHT and/or operation regimes can result in a loss in creep-rupture strength, and
the onset of stress corrosion cracking (SCC).
A well managed program of inspection over the lifetime of the plant is essential to fulfil QA
requirements.
P91 – “Recent Outage Experiences-1”
Integrity NDT recently (Aug/Sept 2012) managed the NDT at Swanbank CCGT (Brisbane Australia)
• Early a accelerated creep detected and monitored in a super-heater outlet leg , resulted in a
bend replacement
Bend removed for

replacement - Creep
measurement points seen
here welded to the
removed bend.
…and replacement bend
reinstatement, shown
opposite.
• A comprehensive Main Steam weld inspection program was undertaken and x60 joints were
tested.
• AUT by TOFD and Phased Array was conducted providing a digital ‘fingerprint’ of the weld
condition, facilitating future monitoring on an on-going basis
• Also, targeted inspection by TOFD and Phased Array have been proven in the detection of
creep damage
Integrity NDT recently (Jan 2013) worked with European Technology Development (ETD) on a
P91 Main Steam Pipeline Inspection Project; at Pearl Energy Quezon Power Plant, Philippines.
Because of a leakage problem at a cracked Main Steam valve reducer weld in July 2012, Station
planned to carry out a significant Main Steam line weld inspection survey.
Inspections carried out x25 Main Steam

pipeline, valve and reducer welds for creep
defect detection.
Scope of inspections for each weld was:

• Ultrasonic TOFD inspection
• Ultrasonic Manual Pulse Echo Inspection
• Metallurgical Replication
• Hardness Testing
• Thickness Measurement
• Magnetic Partical Inspection
QUARTZ - Pipework Inspection Management
Quartz ProGect: A Web based Inspection management solution to assist engineers in the efficient planning
and management of inspection records over the in-service life of a plant asset...
Quartz ProGect: Enables the creation of ‘intelligent’ plant graphics. Users define ‘live’ on screen ‘tags’ to
create links from plant drawings, to a bespoke database management system where all associated original
reports can be stored and easily retrieved.
The powerful database search functions allow easy management of records and individual item and/or
inspection activity current ‘status’
European Union Funded
Research and Development Project
Under 7th Framework Program
CreepImage: Development of Long Term Creep Monitoring Image Based

Technique
Integrity NDT is a SME Partner involved in a €1M EU funded project, with a consortium of 6
participants from England, Spain, Germany, Greece,Romania and Turkey.
3 R&D companies and 3 SME companies are now working on developing a Long Term Creep
monitoring system from September 2011.
The main role of Integrity NDT in this project is; providing advice and guidance to ensure that
the trials and evaluation of the system is as representative as possible of the conditions
encountered in a power plant, and to advise on system to record and manage the results
obtained. Second role is organising exploitation and dissemination activities as Exploitation
Manager of project.
THANK YOU
FOR YOUR ATTENTION
ANY QUESTIONS?
www.integrityndt.com.tr www.integrityndt.com

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INTEGRITY NDT

POWER STATION INSPECTION

Integrity NDT through our extensive experience of Non-Destructive Testing across

Integrity NDT Engineering conventional NDT Services:

Integrity NDT Engineering advanced NDT Services:

CCGT Power Plant Inspection Management Services

MANAGING WORKSCOPE (SIMD)

• Pre-planning; access and preparation requirements with Station Engineering

• Creating Site Team

• Uploading the workscope to Integrity Site Inspection Management Database

Supervisor NDT Level III

Assistant Supervisor NDT

1. Uploading the Planned Workscope into SIMD

TASK PACK Includes :

All results and related information (photos,

TASK PACK SIMD INSPECTION SUPERVISOR

1. Workscope upload to SIMD

2. Live inspection activity STATUS , search and output report

3. Inspection findings and ‘’ REFER STATION ‘’ tracking / reporting

4. Emergent work additions and tracking / STATUS with MANHOURS

5. Outage summary reporting and final SIMD STATUS tracking completition

• TURBINE (GT & ST ) AND GENERATORS

Bend removed for

Inspections carried out x25 Main Steam

Scope of inspections for each weld was:

CreepImage: Development of Long Term Creep Monitoring Image Based

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