Power Plant Inspection Services
Integrity NDT continue to support our Power Plant clients. We are the approved supplier providing year-round Inspection Management Services and Support to a number of Power Plant clients worldwide.
..working in accordance with our own suite of inspection procedures and techniques, we ensure that the correct techniques and procedures are applied, by appropriately qualified and experienced operators..
With our valued experience we work alongside our client engineering departments and provide a professional plant NDT Support Service. Using our own NDT Procedures we have the knowledge of the plant to be inspected and the types of defects expected. We ensure that all work is carried out and reported efficiently and in compliance with the requirements of the relevant standards and codes. The team is independent of both Main Contractor and Service Inspection Companies and works in close association with the client.
From Pre-Outage Planning Stages, through to the provision of Professional Inspection and Summary reports at close-out, Integrity NDT work with our client partners to ensure that outage NDT is not only cost effective and efficient but also makes a significant contribution to Plant Integrity and Asset Management
QUARTSITE …IT IS THE USE OF OUR IN-HOUSE DEVELOPED TASK SPECIFIC SOFTWARE SYSTEMS WHICH SIGNIFICANTLY ADDS VALUE TO OUR ASSET MANAGEMENT APPROACH TO PROJECT MANAGEMENT FROM OUTSET TO DELIVERY..
We provide commercial Outage Management Software `QUARTSITE` into which we upload the outage programmed inspection activities. The software is designed specifically to manage and track individual task status, and control stored Outage QA/QC requirements. Throughout the project duration, `QUARTSITE` provides vital up-to-the-minute Inspection Status Reports for every inputted activity, through to the final detailed Test Reports produced at Project Close-Out.
The use of this software to control and manage work scope activities creates real efficiencies in the following areas;
- Defines the precise inspection work scope and the tests to be applied.
- Provides `Work Pack` Instructions to Inspection Personnel, including specification of the procedures and techniques to be applied.
- Monitors and controls the progress and status of inspections, providing the client and other site teams with regular reports on progress, status and any items with commercial implications.
- Processes results through established acceptance criteria or through metallurgist or plant specialists
- Ensures that all activities are completed, the QA `loop` is closed out, and the plant made available for service in the desired timescales
- Produces comprehensive controlled electronic Inspection Reports.
PRE-INSPECTION SURFACE PREPARATION…USING A DEDICATED TEAM OF OPERATIVES UNDER DIRECT INSTRUCTION AND GUIDANCE FROM OUR ENGINEERING TEAM WE NOT ONLY ADD TO THE INSPECTION QUALITY BUT ALSO MAKE CONSIDERABLE COST SAVINGS BY OUR DIRECT MANAGEMENT/CONTROL POLICY..
Pre-inspection surface preparation – We provide surface preparation operatives, or can manage subcontracted operatives. Using a dedicated team of operatives under direct instruction and guidance from our Engineering team we not only add to the inspection quality but also make considerable cost savings by our direct management/control policy. By managing the surface preparation activities directly we ensure high levels of surface preparation are achieved, essential to inspection applications, from standard surface inspection methods MPI and DPI, to manual and advanced ultrasonic tasks.
Our philosophy is to ensure that the work is carried out “right first time” rather than have inaccurate data or embark on a programme of rectification. The team will work with the client coordinating key interfaces on site that allow access to and preparation of inspection areas, while presenting clear status and progress reports at outage meetings from our work management software.
Audit re-inspections and assessment of subcontracted inspection works and activities. Through our management services and at the request of our clients, we can provide this service which adds a significant contribution towards ensuring that the work programme is completed within the original time scales and to the desired level of quality.
Our audit policy is not to ‘police’ inspection activities, but to develop teamwork with subcontracted inspection services, using experienced engineers to offer assistance and guidance on items under inspection where necessary.
USING OUR IN-HOUSE DESIGNED SEMI-AUTOMATED `I-SCAN` SCANNER SYSTEMS`…SIMPLE TO USE AND VERSATILE SINGLE AXIS SEMI-AUTOMATED PHASED ARRAY AND TOFD SCANNERS
Integrity NDT ‘i-Scan’ Modular Scanner System
Initially designed for in-house use and continually under development, we design and manufacture semi-automated ultrasonic scanners for TOFD, Phased Array and bespoke applications.
Advanced ultrasonic applications – With particular relevance to PP Main Steam Pipework weld inspection, from the improved efficiency of inspections and greater accuracy in defect detection, sizing, to the on-going monitoring facilitated by the production of electronic data, AUT inspection offer many advantages. Using our in-house designed semi-automated ‘I-Scan’ scanner systems’…simple to use and versatile single axis semi-automated Phased Array and TOFD Scanners, we employ AUT applications; TOFD/Phased Array/Supplementary MUT typically on Steam pipework weldments.
Metallurgy Services – We provide Materials Testing and Metallurgical services and metallurgical analysis. Our services include both field application, including material replication, material identification (PMI) and laboratory analysis, providing our clients with important, identification of life-limiting mechanisms, characterisation of defects, and sampling and testing of ex-service material.
QUARTZ … PROVIDING PP ENGINEERS WITH A POWERFUL MEANS FOR PLANNING INSPECTION REGIMES AND COMBINES THE EASY CONSOLIDATION AND ANALYSIS OF REPORTED INSPECTION RESULTS AND DATA.
Quartz: a web based inspection management solution developed for planning and maintaining records over the pre and in-service life of a plant asset. The management of industrial plant and particularly pipe systems is reliant on detailed system drawings, with unique identification assigned to critical items such as welds, hangers, and bends on pipework systems for example…and therefore particularly relivant to `main steam pipework systems`. From available plant drawings and site surveys, Quartz links scaled 3D CAD pipework modelling, through `live` on screen tags, to a bespoke database of inspection records and a document management system, with the ability to attach original documentation, providing PP engineers with a powerful means for planning inspection regimes and combines the easy consolidation and analysis of reported inspection results and data.
Based on our experience of both Gas and Steam Turbine Plant, Integrity NDT offers a wide range of associated inspection applications and specialist techniques.
Alongside our client partners the implementation of a proven approach to the selection, and application of a planned programme of works adds significant value to plant reliability and asset management.
Main inspection methods are:
- Visual Inspection
- Liquid Penetrant Inspection
- Magnetic Particle Inspection
- Eddy Current Testing
- Ultrasonic Testing
- Phased Array Ultrasonic Testing
- Metallographic Investigation (Replication)
Integrity NDT can help ensure the safe and economical operation of your turbine. Our extensive experience can help you to maximize turbine availability.
As a part of ongoing structured plant asset management, Boiler and Plant reliability can be greatly improved by the implementation of a proven approach to the selection and application of NDT inspection techniques.
A wide range of NDT techniques are available for the condition assessment of Boilers and Boiler Plant, Integrity NDT offer a ‘consultancy service’, bringing together our in-depth knowledge of these applications and our extensive Plant Inspection experience to select the most appropriate techniques to each case.
Main HRSG and Power Piping NDT Services:
- Visual inspections (including videoscope inspections)
- Liquid Penetrant Inspection
- Magnetic Particle Inspection
- Ultrasonic Inspection
- Oxide Thickness Measurement
- Phased Array Ultrasonic Inspection
- Time of Flight Diffraction (TOFD) Inspection
- Metallographic Investigation (Replication)
- Material Analysis and Hardness Measurements
Included in our Power Plant Inspection Management Services, Integrity NDT provide Eddy Current Condenser Tube inspection and comprehensive reporting. Alongside the operational assessment of Power Plant Steam Turbine Generator Condensers, we work with our PP clients to utilise this data in establishing a programmed approach to Condenser Tube Inspection, essential to the prevention of unwanted tube leakage and the avoidance of forced shutdown.
ECT is an established inspection technique used in the examination of non-ferrous paramagnetic tubing such as brass, aluminium brass, cupronickel, stainless steel, and titanium, in Condensers and Heat Exchangers.
Condenser tubes are susceptible to numerous and complex defect types and failure mechanisms, and significant experience is required in the consideration of related failure mechanisms including condenser design, operational and maintenance history, water chemistry, and environmental conditions.
Correct probe type, test frequency and test mode selection are essential in ensuring accurate data collection and analysis of such complex anomalies, and is dependent on material type, wall thickness and condenser design. The detection and evaluation and differentiation between the inner surface (ID) and outer surface (OD), and the difficulties related with defects associated with the presence of the ‘tube support plates’ (conductive material) poses, particularly challenges.
A detailed knowledge of the potential failure mechanisms and failure history is essential information required in determining the probe type(s)/frequencies, probe ‘pull-rates’, and defects sought.
Tube condition assessment and familiarity with optional tube pre-cleaning requirements and cleaning methods, is also essential knowledge in preparation to test and the avoidance of unwanted potential associated damage.
Inspection data analysis requires significant experience and the test results are generated via the inspection system software and presented in colour-coded tube sheet diagrams with legends to identify defect types, severity, and location.