Advanced Nondestructive Examination
The more accurate the nondestructive examination technologies (NDE) used, and the more skilled the inspectors who use them, the more likely that impending trouble at a fossil plant can be quickly identified. State-of-the-art NDE services and experienced inspectors are a given at Structural Integrity Associates, Inc. (SI): offerings range from conventional visual inspections, replication, hardness testing, and alloy identification all the way to eddy current, boresonic, and advanced ultrasonic examinations, including time-of-flight-diffraction, micro-time-of-flight-diffraction, linear phased-array, and annular phased-array ultrasonics. SI personnel can even inspect high-energy piping, boiler headers, and tubing with convenient ultrasonics instead of conventional radiography. And nondestructive examinations are only part of SI's services: SI engineers also develop specialized NDE procedures, techniques, and equipment to meet client needs.
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G-ScanSM Long-Range Piping Inspection
Long-range piping inspection has many fossil plant applications: searching for corrosion under insulation, assessing internal corrosion, locating girth welds on steam piping, and screening for pipe and tube wall thinning, to name a few. Long-range guided-wave ultrasonic G-ScanSM from Structural Integrity Associates, Inc. (SI) provides rapid, full-coverage pipe screening, reducing inspection time and facilitating inspection of difficult-to-access locations. G-Scan inspects 100% of the pipe in question, even through bends and branches, and can handle pipe sizes ranging from 2 - 60 inches in diameter, with fluid temperatures up to 300° F, without removing the pipe from service.
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Engineering Analysis & Analytical Assessment
The answers to the toughest fossil plant questions inevitably depend on accurate engineering analysis and analytical assessment. Whether the questions involve inspection planning, serviceability assessments, remaining life predictions, equipment repair, or replacement design, Structural Integrity Associates, Inc. (SI) has the analytical services necessary to find the answers. SI is backed by long-time expertise in finite-element stress analysis, 3-D computational fluid dynamics modeling, fracture mechanics, probabilistic analysis, root cause analysis, on-line life consumption monitoring, remaining life assessment, financial risk optimization, and many other analytical techniques. SI employs its own proprietary analysis and assessment codes as well as such industry standards as COSMOSFloWorks™, ANSYS® CFX®, and MPC OmegaPipe, and EPRI® BLESS, SAFER-PC™, PODIS, LPRimLife™, and RRingLife™.
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Welding Engineering & Repair Welding
Durable welding is what holds every fossil plant together. Structural Integrity Associates, Inc. (SI) can help clients ensure the suitability of their plants' welding designs, processes, procedures, and even welding personnel. SI's welding engineering staff — many of them involved with ASME Code-making committees and working groups, and all of them knowledgeable in ASME, AWS, and API Codes — are always on hand to review plant welding programs; select and develop welding processes; qualify weld procedures, weld training, and welding personnel; conduct third-party reviews; audit or inspect welding vendor shops; and ensure weld code compliance. SI repair welding staff are also at the ready with innovative specialty repairs for challenging situations, remediation of weld failure root causes, and on-site welding technical support.
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Materials Testing & Evaluation
Materials science is often the bottom line in solving fossil plant problems, and the Structural Integrity Associates, Inc. (SI) state-of-the-art Materials Science Center in Austin, Texas, is more than prepared to assist clients with metallurgical assessments, failure analysis, materials selection, and everything else related to the range of materials used in fossil units. A sampling of the Austin laboratory's capabilities includes optical metallography, scanning electron microscopy, quantitative microstructural analyses, fractography, scale and deposit analyses, metal chemical analyses, cryo-cracking, in-place metallography and replication, miniature sampling, creep and corrosion testing, and mechanical testing.
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Outage Planning & Support
The planning and execution of fossil plant outages stretches plant staff to the utmost. When outage season looms, it may be reassuring to know that the engineering and technical staff of Structural Integrity Associates, Inc. (SI) are on standby to help industry clients with every outage assignment: planning, condition assessment, repairs, nondestructive examination, stress and fracture analyses, materials and process selection, financial-based optimization, and more. SI's expertise encompasses all plant components and systems, including turbine-generators, boilers, piping, headers, combustion turbines, and balance of plant.
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Technical Training Programs
Top-notch training programs produce engineering and operating staff ready to run trouble-free, cost-effective fossil plants. The collective expertise and industry experience of the professional staff of Structural Integrity Associates, Inc. (SI) is available to clients via technical short courses that cover all aspects of fossil plants, including advanced nondestructive examination, boiler tube failure reduction, high-energy piping management, flow-accelerated corrosion control and prevention, cycle chemistry, and asset management for new creep strength-enhanced ferritic steel components. In addition to offering a roster of pre-prepared training courses, SI can also develop customized courses for clients' specialized needs, including specific plant applications. All courses can be presented at either SI offices or the client's location, or via convenient Webinars.
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Financial Risk Optimization
Fossil plant run/repair/replace decisions are often tough calls, further complicated by aging equipment and dwindling repair and replacement budgets. Structural Integrity Associates, Inc. (SI) offers clients a methodical approach to financial risk optimization (FRO), using decision analysis methods now employed by corporate financial planners. Based on failure history data and in-depth plant personnel interviews, SI's FRO approach determines highest-risk components and estimates their probability of failure over time. Inspection results and probabilistic remaining life analysis are then used to fine-tune determinations of the highest-risk-driving components and how they affect run/repair/replace decisions. The end result: a financial business plan for plantwide maintenance.
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On-Line Monitoring
The rates of damage accumulation and crack growth of many fossil plant components are strongly influenced by their particular temperature and pressure histories. Detailed temperature and pressure operating data are therefore indispensable for accurate stress histories and improved life assessment calculations, but this crucial data can only be captured by constant on-line monitoring. Fortunately, Structural Integrity Associates, Inc. (SI) is well-equipped to deploy advanced on-line monitoring systems on components of interest, particularly those susceptible to creep fatigue due to strenuous cycling conditions.
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