Latest news / events
- TWI gets high visibility at Middle East NACE Conference
- TWI assists with critical repair at Canadian nuclear plant
- Successful launch of the Energy Generation and Supply KTN
- TWI Leading the Development of In-Situ Structural Monitoring of Offshore Wind Towers and Blades
- Seminars in Thailand well received
- Wind Turbine Foundation Production - new process undergoing trials
- Metal Texturing and Surfi-Sculpt
- TWI heads up UK's new energy generation and supply Knowledge Transfer Network
- Materials issues surfacing and particulate engineering
- High Power Lasers for Nuclear Decommissioning
- TWI sets up P91 component integrity solutions activity.
- RISKWISE to be implemented on JEV 1400MW coal-fired power plant in Malaysia
- Risk management seminar is a success for Malaysian safety regulator
- High Profile for TWI in SE Asia
- Renewable Energy Centre operational at TWI's Technology Centre (North East)
- ALERT- Safety and Reliability Concerns with P91 Pressure Vessels and Piping
- TWI co-chairs energy materials task group on alternative energy
- Friction stir processing being developed for on-line repair of nuclear plant
TWI gets high visibility at Middle East NACE Conference
Dr Iba Al-Adel, a past National Association of Corrosion Engineers (NACE) President presents Brian Cane with a gift after his invited plenary lecture at the 13th Middle East Corrosion Conference in Bahrain in February 2010. Dr Cane's paper on 'Operational Excellence through Asset Maintenance Optimisation' included a series of illustrative RISKWISE case studies and was the opening lecture at the conference which was attended by more than 600 delegates worldwide. Dr Chi-Ming Lee from TWI's Materials & Corrosion Group also presented a paper on Corrosion Resistant Alloys at the conference.
For further information, please contact: power@twi.co.uk
TWI assists with critical repair at Canadian nuclear plant
Nuclear expertise, developed by TWI over the last half century, has recently been called upon by a major nuclear operator.
Atomic Energy of Canada Limited (AECL) is collaborating closely with third-party welding experts The Welding Institute (TWI), UK based global specialists in materials joining technology on a highly specialised repair to an aluminium reactor vessel. TWI is helping with the development and testing of welding techniques in what AECL describes as a unique and challenging environment.
The NRU reactor is responsible for producing approximately 30% of the global supply of medical isotopes, used for radiotherapy and other medical treatments. There is virtually no published data on welding of irradiated aluminium, and TWI has been instrumental in advising AECL on development of the specialised repair techniques required for this task.
The first weld build-up inside the NRU reactor vessel was successfully performed on December 12th 2009. The weld repair was conducted remotely by operating the welding equipment from a position of approximately 10 metres above the location of the repair site.
Non-destructive examinations of the weld have found no defects, and preparations are now underway to conduct further repairs.
Successful launch of the Energy Generation and Supply KTN
The Knowledge Transfer Network (KTN) enjoyed a highly successful launch at Innovate 09 on 13 October. For the KTN the launch started with the main Stage panel session on Growth Opportunities in Energy Generation and Supply and featured David Kidney, Parliamentary Under Secretary of State, Department of Energy and Climate Change; Henri Winand, Chief Executive, Intelligent Energy Plc; David Grant, Vice-Chancellor of Cardiff University and Governing Board Member of the Technology Strategy Board and Nick Winser, CEO, National Grid.
Following the panel session Dr Brian Cane, Director of the EG&S KTN, hosted a workshop on Supporting and Enabling Innovation in Energy. The session, which also featured a presentation from Trevor Raggat from the Department of Energy and Climate Change included representation from the Technology Strategy Board, the Energy Technology Institute, the Research Councils and The Carbon Trust, and attracted over 100 people leading to a 'standing room only' event.
To see Dr Cane explaining more about the KTN please go to http://www.innovate09.co.uk/video15.aspx
To find out more, please contact: enquiry@energyktn.innovateuk.org or brian.cane@twi.co.uk.
TWI Leading the Development of In-Situ Structural Monitoring of Offshore Wind Towers and Blades
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With the push for the global renewable offshore wind industry, TWI is leading a strong consortium of UK companies in the development of a complex non-intrusive monitoring system to provide a complete analysis of the wind turbines structural health in operation.
In a wind turbine, the composite blades can suffer fatigue failure and towers are susceptible to corrosion and fatigue. These components require regular inspection to avoid catastrophic failure risk. Current inspection methods can only be performed offline, through human intervention, with limited volume coverage and are cumbersome, time consuming, hazardous and expensive.
The INSIGHT project will develop novel technology to continuously monitor offshore wind tower structures and turbine blades, using inductive displacement sensors (IDS) for the blades and the long range ultrasonic (LRU) and acoustic emission technique (AE) for the towers. Data will be transmitted to shore by either microwave or optical fibres to provide operational contingency.
The INSIGHT system will address the complex technical requirement, hazardous operational environment and the economic and safety needs in continuous remote monitoring of offshore wind turbine structures, thus bringing the industry benefits in reduced operational costs through minimising costly site visits with more efficient maintenance plans, increased availability by reducing down time and reduced insurance costs.
The project brings together a strong team of supply chain stakeholders in the offshore wind industry, comprising TWI, RWE Npower, Ericsson, Solent Composites, Fugro Structural Monitoring, TUV NEL, University Of Warwick, Ultra Electronics, Novalia, Physical Acoustics Ltd, Spree Engineering, I.D.E.A.S. and Zettlex.
INSIGHT is a £2m project part funded by The Technology Strategy Board. The Technology Strategy Board is a business-led executive non-departmental public body, established by the government. Its role is to promote and support research into and development and exploitation of, technology and innovation for the benefit of UK business, in order to increase economic growth and improve quality of life. It is sponsored by the Department for Business, Innovation and Skills (BIS). For more information about the Technology Strategy Board please visit www.innovateuk.org.
Further information on INSIGHT can be found on www.insightproject.co.uk or by contacting its Project Manager - Dr Chiraz Ennaceur (chiraz.ennaceur@twi.co.uk, + 44 (0)1223-899000).
Seminars in Thailand well received
| TWI's Brian Cane and Ian Partridge with members from Thai Non Destructive Testing pcl |
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Thailand was the venue for two successful TWI seminars on Risk-Based Asset Management and Life Assessment. With organisational support from Thai Non Destructive Testing pcl (TWI's local representative company in Thailand) the events attracted around 30 delegates from power, oil & gas and chemical companies. The seminars, held in Bangkok and in the industrial zone of Rayong, received highly positive feedback with most interest centred on risk based inspection.
For further information, please contact: power@twi.co.uk.
Wind Turbine Foundation Production - new process undergoing trials
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A new process aimed at production of wind turbine foundations is under trial at TWI's Low Carbon Energy Manufacturing Technology Centre in Middlesbrough. The process, known as Reduced Pressure Electron Beam (RPEB) welding developed at TWI allows welding of steel up to 150mm thick at rates of 100mm per minute.
The deployment of wind turbines offshore has driven designers to maximise the power output capability of each installation. An integral step in the development of higher power wind turbines is the manufacture of larger towers and deep water foundations for offshore installations. Such parts are likely to involve weld section thickness of up to 150mm and currently arc-welding techniques limit the production speeds and increase the cost of the parts. The high production rate and large number of wind turbines required for offshore programmes necessitates a reduction in manufacture time and cost.
RPEB welding is an advance on conventional electron beam welding which uses a work chamber that completely envelops the component to be welded. The work chamber is evacuated to produce a high level of vacuum, prior to the welding process. RPEB welding allows the electron beam process to be used on much larger components, by relaxing the vacuum requirements and through the use of local sealing, but without compromising the weld quality and the high weld production rate.
Wind energy will not be the only industry to benefit from the process. Thick section welding in new nuclear build is also being addressed. For more information please contact the power team.
Metal Texturing and Surfi-Sculpt
A novel process for improving metal to composite joints is now available at TWI's Low Carbon Energy Manufacturing Technology Centre. Surfi-Sculpt employs an electron beam to produce surface protrusions at high speed. The features of typically a few millimetres height can be used to prepare a metal surface to be joined to composite - the protrusions ensure that multiple plies of the composite fibre interact with metal surface, thus enhancing bond performance.
The surfi-sculpt process has potential application for wind turbine blades. It also has a variety of other uses such as: light weighting of vehicles, improving heat transfer and bone-metal joints in medical implants.
TWI heads up UK's new energy generation and supply Knowledge Transfer Network
TWI has won a high profile contract to lead the Energy Generation & Supply Knowledge Transfer Network (EG&S KTN) following an invitation to bid from the UK Government's Technology Strategy Board.
Through coordinated technology and innovation, a major objective is to accelerate the UK's uptake of the huge energy business opportunities in the UK and globally. In accord with the Technology Strategy Board's EG&S strategy for 2008-2011, the KTN will focus on several technology areas: offshore wind, wave and tidal, carbon abatement technologies (including higher efficiency plants, biomass co-firing and carbon capture & storage), hydrogen and fuel cells, maximising oil & gas resources and future emerging opportunities.
TWI will lead a strong delivery team comprising AEA Technology, APGTF (Advanced Power Generation Technology Forum), ITF (The Industry Technology Facilitator), Synnogy and UKERC (UK Energy Research Centre).
The EG&S KTN is referenced within the UK Government's 2009 Low Carbon Transition Plan: "It will promote collaboration and knowledge sharing between developers nationally and internationally and in so doing, enable industry to identify suitable funding opportunities. UK and EU grant and support schemes for energy generation technology developers are provided by a number of bodies and can be seen as confusing and hard for developers seeking funding to navigate. The Knowledge Transfer Network will act as a 'front door' helping developers navigate the UK and EU funding landscape so they receive the best support available to progress their technology development".
The EG&S KTN aims to engage with the growing population of stakeholders and map on to existing networks within the EG&S landscape. Membership of the KTN is free of charge and open to the entire energy community, including industry, investor, academia, innovators, government bodies and regulators.
Registered EG&S KTN members will benefit from access to advisory services aimed at facilitating business and technological success, for example in R&D funding and collaboration building, project financing, supply-chain opportunity, technology investment and updates, market and policy information. These services will be delivered through an interactive web portal, Enquiry Helpdesk as well as networking and partnership brokering events. Special Interest Groups are also planned to address focus areas that are cross-cutting and strategic to the growth of the UK energy industry.
Dr Brian Cane, Head of TWI's Power and Energy Systems, appointed the EG&S KTN Director has stated that: "The new KTN provides a great opportunity to speed progress towards UK Low Carbon economy and energy security targets and I intend that it will deliver real and measureable benefits to the Energy Generation & Supply community".
The EG&S KTN will be formally launched at the Technology Strategy Board's 'Innovate 09' event at the Business Design Centre, Islington, London on 13th October 2009.
Dr Brian Cane leads a TWI KTN operation team with day to day management performed by Chris Bagley (Network Manager) and Dr Nee Joo Teh (Enquiry Management and Special Interest activities).
Further information about the proposed new network, and details of how to express an interest, can be found at: www.innovateuk.org/energyktn
Materials issues surfacing and particulate engineering
WJS Materials Technical Group Meeting held at TWI Conference Centre on Tuesday 2 June 2009
The Welding and Joining Society hosted the anticipated Materials Technical Group Meeting on Tuesday 2 June 2009 at TWI Cambridge Conference Centre and captured both the historical and present issues on the subject of surfacing and particulate engineering, through discussions and presentations from Rolls Royce, Atomising Systems, Hoganas, Leicester University and TWI. The highly successful meeting was co-sponsored by the Particulate Engineering Committee of IOM3.
This one day event included a tour of TWI Surfacing facilities for a demonstration of thermal spraying as well as a visit to the TWI library for a brief introduction to the information services with a particular focus on the latest MI-21 data base (www.mi-21.com, a new service run by TWI in collaboration with NAMTEC and World Metal Index).
Delegates had a chance to network and establish contacts throughout the day. Those, particularly interested in professional development were encouraged to join WJS, The Welding Institute and IOM3, and informed of benefits of professional membership and the registration with the Engineering Council towards for example, CEng status.
For a full summary of this meeting and further information on future meetings of the WJS Materials Technical Group, please contact directly the secretary, Dr. Cem Selcuk at cem.selcuk@twi.co.uk
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Left to right: Chairman, Peter Boothby (Macaw Engineering) and speakers: Jeffrey Allen (Rolls Royce), Roger Fairclough (TWI), John Dunkley (Atomising Systems), Paul Nurthen (Hoganas) and Dave Harvey (TWI) with Secretary, Cem Selcuk (TWI) |
RISKWISE to be implemented on JEV 1400MW coal-fired power plant in Malaysia
| JEV Power Plant under construction March 2008 |
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TWI has been contracted to perform a risk-based inspection (RBI) study at JEV Power Plant in Malaysia. The RM6bn (£1bn) 1,400MW coal-fired Jimah plant, owned by Jimah Energy Ventrures Sdn Bhd is located at Mukim Jimah in Negeri Sembilan, Malaysia.
The plant is due to enter commercial operation in January 2009. Working closely with Jimah O&M Sdn Bhd (JOM), the O&M contractor for the plant, TWI will implement RISKWISE for Boilers version 4 on the two 700MW boilers. The primary objective of the three-year project is to maximise the reliability of the boiler plant by reducing the risk exposure to unplanned or forced outages. At the same time, the work aims to achieve an extension to statutory inspection intervals compliant with Dept of Safety & Health requirements. The early implementation of RBI at this plant is to establish the baseline condition as a reference for future inspection and assessment.
The project will be led by TWI Services out of TWI's South East Asia offices in Kuala Lumpur.
Risk management seminar is a success for Malaysian safety regulator
A one-day seminar to the Department of Occupational Safety and Health (DOSH) was held at Putrajaya in Malaysia in November.
DOSH is a department under the Ministry of Human Resources. This department is responsible for ensuring the safety, health and welfare of people at work as well as protecting other people from the safety and health hazards arising from industrial operations. As a government agency, the department is responsible for the administration and enforcement of legislations related to occupational safety and health throughout Malaysia.
The seminar was organised by TWI Services Sdn Bhd with the purpose of increasing awareness on risk and integrity issues in petrochemical, power and process plants. TWI's technical presentations were made by Ian Partridge, Chen Fun Wee and Dr Brian Cane covering asset integrity management issues including risk-based inspection and fitness for service assessment.
Attendees included around 30 participants. These were from the federal headquarters of DOSH as well as from DOSH units throughout the Malaysian states.
Contact felix.fernadex@twisea.com or brian.cane@twi.co.uk for further information.
High Profile for TWI in SE Asia
TWI's Head of Power & Energy Systems, Dr Brian Cane presents at the International Energy Security Forum in Kuala Lumpur.
This was a high level forum sponsored by the Malaysian Government, the Ministry of Energy, Tenaga Nasional Berhad (TNB) and the Institute of Strategic & International Studies, with the primary objective of assisting Malaysia in formulating a comprehensive national energy security policy.
Dr Cane was one of six international invited speakers who included experts from BP, International Atomic Energy Agency and energy advisory consultants from USA and Hong Kong. The forum was opened by the chairman of TNB. Dr Cane's presentation 'Key Issues for a Sustainable Energy Security Strategy' was within the session on policies and strategies for energy security.
Over 300 participants from 23 countries attended the one-day forum. The event, which was held at the Shangri-la Hotel, Kuala Lumpur on 12 November 2008, was organised by Paddy Schubert Consultants Sdn Bhd. The forum was televised and reported in the Malaysia and Japanese press as well as in Bloomberg, the leading global provider of financial data.
For more information please contact brian.cane@twi.co.uk
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From left: Mark Henstridge (Director, Group Economics BP London); Dr Brian Cane (Head of Power & Energy Systems, TWI Ltd, UK); Datuk Dr Paddy Bowie (Managing Director, Paddy Schubert Consultants); Tan Sri Leo Moggie (Chairman of TNB); Dato Sri Che Khalib Mohamad Noh (President and CEO, TNB); Ferenc Toth (Senior Energy Economist, International Atomic Energy Agency [IAEA]);Dato Abdul Razak Abdul Majid (Senior Vice President, Corporate Affairs, TNB); Dr Mohd Zamzam bin Jaafar (Head of Nuclear Energy Task Force, TNB) |
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Dr Cane with TNB's CEO, Dato' Sri Che Khalib Mohamad Noh |
Renewable Energy Centre operational at TWI's Technology Centre (North East)
With funding support from One NorthEast, Government Office, European Regional Development Fund and the Tees Valley Partnership, the Renewable Energy Manufacturing Technology Centre (REMTEC) is now operational. The new centre, part of TWI's regional expansion programme, is located at TWI's existing facilities in Middlesbrough.
The centre will carry out research, technology transfer and training to support the development, validation and demonstration of innovative design and manufacturing solutions for existing and emerging new and renewable energy sources.
With its leading-edge fabrication and processing technologies, the new REMTEC facility will step-up TWI assistance to local companies sited in the North East, integrate with universities and existing centres of excellence and attract inward long-term investment from national and overseas organisations.
One NorthEast is also supporting a TWI-led technology transfer programme, which is providing free technical assistance to engineering SMEs and is helping manufacturers insert technology and develop capabilities for efficient product development and improved manufacturing processes.
Using specialised expertise at REMTEC, the technology transfer programme has already provided advice or in-depth assistance to around 200 firms in the North East and created over 80 new jobs and safeguarded nearly 150 jobs with increases in business turnover.
With the new REMTEC facility TWI will have additional capability to support a wide range of development projects covering several new and renewable energy areas. In each case, the projects will be aimed at demonstrating the benefits of the technology as well as stimulating market demand supported by technology transfer with underpinning skills training and qualifications for development of the workforce.
Contact power@twi.co.uk for further information.
ALERT- Safety and Reliability Concerns with P91 Pressure Vessels and Piping
This note to you to ensure that power plant operators are alerted to the current industry concerns regarding the integrity of Grade 91 steel piping and boiler headers in elevated temperature service.
Grade 91 steel was introduced in the 1980s as an advanced ferritic steel and has been used extensively since then as P91 in high temperature headers and steam piping in new plant as well as in retrofit refurbishment applications.
Evidence from recent premature weld failures in P91 steel together with long term data on cross-weld samples now suggests that design may be non-conservative for P91 welded pressure vessels and piping. Incidences of cracking in P91 welds have been reported in times significantly less than 100,000hours leading to safety and reliability concerns worldwide.
As a result, ASME is considering a reduction in the allowable stress for P91 welded pipe. Consequently, the stress imposed on a welded pipe currently being commissioned or in service is greater that which is now allowable. In turn, the expected lifetime may be reduced considerably. The performance of P91 components is also highly sensitive to fabrication heat treatment and there have been instances where improper control has led to worries regarding premature failure.
TWI is amassing an industry experience database in this area with the aim of assisting plant operators to assess the risk of premature failure. To find out more please contact brian.cane@twi.co.uk.
TWI co-chairs energy materials task group on alternative energy
Reporting into MatUK*, the remit of the Energy Materials Working Group is to develop a Strategic Research Agenda and Deployment Plan for the UK Materials supply chain which will improve profitability in the sector whilst meeting the key energy-related challenges of sustainability, environment and security of supply facing the UK.
The Alternative Energy Task Group co-chaired by Dr Brian Cane of TWI will include materials issues related to: biomass, waste and co-firing, solar, wind, wave & tidal, fuel cells, hydrogen, biofuels, etc.
The Task Group will define the drivers, barriers, roadmap for R&D and its implementation plan over the next 20 years including the impact on the UK materials industry.
For further information please contact: power@twi.co.uk
*Mat UK is a body set up by the Materials Innovation & Growth Team (Materials IGT) which was created in October 2004 and approved by the Secretary of State for Trade & Industry.
Friction stir processing being developed for on-line repair of nuclear plant
| Friction stir processing trial - stainless steel |
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As nuclear plants around the world grow older there are increasing incidences of stress corrosion cracking (SCC) problems.
In PWRs such cracking is well known and often associated with reactor pressure vessel parts (eg: primary water SCC at reactor nozzle locations). However SCC also occurs in the secondary circuit and auxiliary parts of the plant which are also safety-critical.
This repair development is aimed at relatively thin-walled Type 304 stainless steel water storage tanks which have experienced SCC cracks at the external surface. Friction stir processing is a technique which has grown out of TWI's friction stir welding expertise and essentially provides a high integrity smooth repair of shallow surface breaking defects. For this particular application, the utility customer considered it offers advantages for in-situ application particularly in terms of its controllability and lower risk of through-wall penetration when compared with conventional weld repair methods.
For further information please contact power@twi.co.uk
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