Critical Component Repair and Systems Fabrication
A large percentage of new power generation in the US over the next 10 to 20 years will be provided by new combined cycle type plants. These combined cycle plants are often running at higher temperatures than initially designed. In addition, conventional fossil plants are being relied upon for continued service well long beyond their intended or design life. This results in damage to critical piping and pressure part components that limit and/or suspend the continued operation of the plant. Very rarely is replacement a practical or economic option; therefore, repair and remediation of the damage is the only viable solution for returning the component to a safe and serviceable condition. However, repair and/or remediation of an aged component is not a simple task and requires extensive expertise in systems, design, metallurgy, inspection, machining and welding.Structural Integrity has brought together the necessary resources to properly and comprehensively manage critical component life for new or existing plants: including design, procurement, fabrication specification development, fabrication, construction specification development, Installation, and Comprehensive Baseline Data Package. Furthermore, only Structural Integrity has demonstrated the ability to apply the same robust, broad-based expertise to the identification of damage root cause, development of appropriate and cost-effective remedial actions, and implementation of repair technologies to ensure safe continued operation of damaged critical components.
Our Solution
We established a strategic alliance with Wachs Energy Services Company (WES) to provide the conventional fossil and combined cycle power plants owners/operators with a comprehensive solution for the repair, remediation, fabrication, and erection of critical pressure parts and systems service. By working together, we bring our highly technical, engineering expertise to fossil and combined cycle plant critical component assessments from advanced non-destructive examination to root cause analysis, metallurgical analysis at our in-house metallurgical lab, stress analysis, finite element modeling, fitness for service and providing remaining life assessments. While WES brings unmatched precision field machining, shop and field welding services, craft labor manpower augmentation and expertise in boiler mainteneace, facility decommissioning and new construction projects.
|
Item |
Service |
Service Description |
Details/Components of Service |
|
1 |
Initial Design Review |
Verify the soundness of technical decisions such as weld design and location, maximum design temperatures in heat transfer areas, etc. |
Review of drawings, design calculations, etc. and identification of weaknesses requiring modification based on predicted performance of material |
|
2 |
Material Procurement |
Provide specification of optimum chemistry and heat treatment (i.e., tempering parameter appropriate for the specific application intended) and, as appropriate, supplier surveillance, including inspection and testing, to verify compliance with all critical requirements |
1. Review of mill practice. 2. Mill inspection, as appropriate, to verify continuous compliance with critical requirements. 3. Testing, as necessary, to document continuous compliance. |
|
3 |
Fabrication Specification Development |
Development of new or approval of existing procedures for welding, bending, heat treatment, etc. Where appropriate, QA surveillance of the fabricator, including inspection and testing, as necessary |
1. Review of fabricator’s in-house procedures to identify variances from desired practice. 2. On –site inspection, as appropriate, to verify continuous compliance with all critical requirements. 3. Testing, as necessary, to document continuous compliance. |
|
4 |
Fabrication |
Where piping or other thicker-walled components are involved, assume fabrication responsibility with all required inspection, testing, etc |
1. Fabrication of piping components to manufacturers’ specifications and applicable Code Requirements. |
|
5 |
Construction Specification Development |
Where an outside contractor will install the components; to include development of new or approval of existing procedures for welding, heat treatment, etc. Where appropriate, QA surveillance of the contractor, including inspection and testing, as necessary |
1. Review of contractor’s procedures to identify variances from desired practice. 2. On-site monitoring to verify continuous compliance with all critical requirements. 3. Testing, as necessary, to document continuous compliance. |
|
6 |
Installation |
For piping, headers, etc., assume installation responsibility with all required inspection, testing, etc |
Through our partnership with Wachs, provide a turnkey installation of the critical components Ensuring the highest quality installation meeting all applicable codes and standards as well as incorporating the highest technical expertise in the industry |
|
7 |
Comprehensive Baseline Data Package Development |
Supply a comprehensive data package documenting satisfactory results of all monitoring, testing, inspection, etc. |
This will meet all applicable Codes and Standards and will serve as the basis for subsequent life assessment monitoring |
Give us a call for more information or request a proposal.
Related Brochures:
Related Press Releases:
Related Products and Services:
- Advanced Nondestructive Examination
- Root Cause Analysis
- Metallurgical Analysis
- Stress Analysis
- Finite Element Modeling
- Fitness for Service
- Remaining Life Assessments