CRC for Welded Structures

Pacific Power International has been involved off site inspection of plant & equipment for construction of power stations installed with 660MW, 500MW and 350MW units, since the Electricity Commission of NSW was formed in the early 1950's.

These inspections are backed up by the resources of the Plant Life Management Branch in Technical Services, where expertise such as remaining life assessment, fractography, corrosion/coatings, failure analysis and structural integrity and in-service inspection are available in-house to a world class standard. The branch has contacts in a national and international network, which ensure it remains abreast of all important damage mechanisms, failure types and repair techniques occurring world wide and in similar plant to that installed at NSW Power Stations. The branch also actively undertakes research and development in such important areas as plant cycling and component life extension. In the field of integrity of welded high temperature structures such as seam-welded headers and steam mains, PPI is recognised as a world leader. Where the solution of problems may require expertise outside the metallurgical field, in-house skills are available within PPI in the areas of process chemistry, stress analysis, machine condition monitoring, thermodynamics and efficiency, which are also available to our inspectors.

Pacific Power International / Technical Services / Plant Life Management have also developed a number of in-house standards that cover the technical aspects of fabrication not included in any recognised standard.

Pacific Power International / Technical Services / Plant Life Management has a representation on several Standards Australia committees including AS/NZS 3788, Panel ME1/18.

Technical Services has over 45 years experience providing these services to the power generation industry with a proven track record of improvements in availability & reliability through solving the metallurgical problems of the power generation industry.

Previously, in a regulated environment, plant owners of pressure equipment were required to have inspections carried out by NSW WorkCover Licensed Boiler Inspectors. In the current de-regulated environment, plant owners are required to use "competent persons" to carry out in-service inspection of pressure equipment to the requirements of AS/NZS 3788

Pacific Power International has been involved with pressure equipment certification and inspection since the Electricity Commission of NSW was formed in the early 1950's. Using licensed boiler inspectors, and more recently, third party accredited competent personnel, Pacific Power has performed this task at all its thermal and hydro power stations and transmission sites. With the deregulation of the Power Industry in 1994, Pacific Power International has continued with the inspection of pressure equipment, including 660MW, 500MW and 350MW boilers.

These inspections are backed up by the resources of the Plant Life Management Branch in Technical Services, where expertise such as remaining life assessment, fractography, corrosion/coatings, failure analysis and structural integrity are available in-house to a world class standard. The branch has contacts in a national and international network, which ensure it remains abreast of all important damage mechanisms, failure types and repair techniques occurring world wide and in similar plant to that installed at NSW Power Stations. The branch also actively undertakes research and development in such important areas as plant cycling and component life extension. In the field of integrity of welded high temperature structures such as seam-welded headers and steam mains, PPI is recognised as a world leader. Where the solution of problems may require expertise outside the metallurgical field, n-house skills are available within PPI in the areas of process chemistry, stress analysis, machine condition monitoring, thermodynamics and efficiency, which are also available to our inspectors. Appropriate brochures of these services are attached.

Pacific Power International / Technical Services / Plant Life Management has a representation on the Standards Australia committee which supervises AS/NZS 3788, Panel ME1/18, through Mr Bob Small. His membership of this panel gives an opportunity for the power industry to have an input to this standard, and also means the industry is kept up to date with the evolution of this code.

Technical Services is located at the Advanced Technology Centre, Newcastle and provides independent technical advice in the areas of:

Technical Services has over 45 years experience providing services to the power generation industry with a proven track record of improvements in availability & reliability through solving the metallurgical problems of the power generation industry.

The Metallurgical Assessment Branch provides Non Destructive Testing services and has six permanent employees and utilises casual skilled labour as required. The employees have between 6 and 20 year's experience in all aspects of NDT. The Branch was formerly the NDT group of the Metallurgy Section of the Electricity Commission of NSW, and was involved during most of the construction of the operating power stations in NSW from the mid 1950's to the mid 1980's. The main role of the Radiography staff during the construction phase was auditing of contractors, but the group has been providing radiographic services at all NSW power stations over most of this time, especially during breakdowns and planned maintenance. Similarly, ultrasonic staff have audited contractors as well as provided services over most of this period.

Apart from NSW, NDT services have been provided in most states around Australia. Some of the clients have included:
Northern Power Station, SA, Hazelwood Power Station, VIC, Muja Power Station, WA, Loy Yang A Power Station, VIC, Swanbank Power Station, QLD, Caltex Refineries, NSW and QLD.

The Metallurgical Assessment staff has NATA accreditation in the following areas:

Radiographic examination of Ferrous metals - Welded joints, castings & forgings
Radiographic Examination of Aluminium alloys - Welded joints & castings.
Radiographic determination of thickness - Corrosion pitting in pipes
Ultrasonic examinations of ferritic steels - Flat rolled products, welded joints, castings & forgings.
Ultrasonic examinations of aluminium alloys - Rolled products, welded joints & forgings.
Ultrasonic examinations of austenitic steels - Rolled products, welded joints & forgings.
Ultrasonic thickness measurement
Ultrasonic examination of bonded metals - Machine bearings
Ultrasonic examination of finished components in service - Screw threaded components & gears components & splined components.
Magnetic particle testing - Magnetic flow method & current flow method
Penetrant testing - Water washable method, solvent removable method, post emulsifiable method.
Eddy current testing of ferromagnetic materials - Surface flaw detection, sub-surface flaw detection & other specified tests - Flaw detection in tubing by internal testing
Eddy current testing on non-magnetic materials - Surface flaw detection, sub-surface flaw detection & other specified tests - Flaw detection in tubing by internal testing.
Visual inspection - Rolled products, welded joints & forgings plus other specified products - borescope/ video inspection of pipework.

The Plant Life Management Branch also provides comprehensive metallurgical services that complement and support the Metallurgical Assessment Branch in areas of:

Failure and root cause analysis
Fitness for Purpose assessment of defects (Fracture Mechanics)
Condition and life assessment of high temperature components
Diagnosis of corrosion mechanisms, including failure of protective coatings
Weld repair procedures
Material identification by portable XRF
Material selection advice
Pressure equipment inspection & certification
Inspection of both on-site & off-site repairs
Audit contractor's quality system/s.

Back to the Partners