A selection of projects undertaken on behalf of members in the non-nuclear sector of the power industry

• Fossil/Steam Plant
• Gas Turbines
• Renewables

Fossil/Steam plant

• Weld procedure development of dissimilar metal joints
• Examination of the feasibility of EB welding of 150 mm stainless steel shafts
• Diffusion bonding and adhesive bonding of compact heat exchangers
• Joining of oxide dispersion strengthened materials
• Development programme for the flash welding of 12% Cr boiler tubing
• Electron beam welding of steam turbine diaphragms

• Condition assessment of steam riser pipes
• Heat affected zone simulation programme
• Fracture toughness testing of steam riser pipe material
• Assessment of friction weld quality for thick section boiler plate materials
• Assessment of power station boiler header weld flaws
• Examination of scaling on superheater tube support clip attachment weld
• General fillet weld inspection development for internal attachments in boilers
• Examination of a failed steam separator element
• Boiler repair project - independent peer review
• Ultrasonic defect growth monitoring inspections
• Examination of failure fir tree connection in rotor disc from a steam turbine
• Investigation of a failed steam turbine generator outer casing
• Non-destructive testing of large steam turbine rotors
• Assessment of cracking in turbine valve chests
• Development of low cycle fatigue test method for rotor blade slots
• Examination of stress corrosion cracks in steam turbine rotor
• Development and assessment of procedures for repair welding of pressure vessels and turbine rotor casings
• Investigation of cracking in dissimilar metal welds
• Failure investigation of brazed components
• Customisation of RISKWISE ^TM for risk-based maintenance of power station boilers in USA
• Review of risk-based inspection and maintenance (RBI/M) and fitness-for-service assessment methods
• Training and supply of RISKWISE ^TM for risk-based maintenance of power station boilers in Japan
• Cracking investigation in T91 tubing
• Fitness for service assessment of pipe girth weld
• Engineering criticality analysis of power distribution structures

Gas turbines

• Electron beam diffusion bonding of a titanium aluminide alloy
• Chemical analysis and tensile tests on gas turbine base unit
• Examination of the feasibility of EB welding of large diameter turbine shafts
• Simple models for residual stresses in linear friction welds
• High temperature thermal barrier coatings for gas turbine components
• Welding of Hiduminium 54
• Manufacturing and modelling of fabricated structural components (MMFSC)
• Rotary friction welding nickel superalloys
• Linear friction welding of single crystal turbine blade material

• CMSX4 turbine blade repair study
• Examination of creep damaged HP turbine blades
• Engine failure investigation
• Advanced repair of gas turbine blades including IN738 and CMSX4 materials
• Laser powder fusion repair of blades
• Activated TIG repair of blades
• Post-repair performance validation by creep and low cycle fatigue testing
• Repair validation programme for vane assemblies including LCF testing of repairs and thermal modelling
• A review of condition inspection and repair techniques for hot section gas turbine components
• NDT of flame sprayed coating on turbine ring
• Investigation of weld cracking during the manual TIG welding of cooling passages in Inco 82 turbine vanes
• Failure investigation of a failed diffuser support ring from a gas turbine exhaust system
• LP rotor disc failure investigation
• Failure investigation of stainless steel fuel lines
• Examination of failed nozzles. The examination of a number of stainless steel (AISI type 304) fuel injection nozzles from a gas turbine
• Replication inspection of gas turbine rotor disc
• Residual stress analysis of gas turbine exhaust cascade bend assemblies
• Investigation into the mechanism of cracking from a gas turbine uptake system
• Investigation of the cause of cracking in an exhaust diffuser support ring
• Metallographic study of Inconel X750
• Investigation into the cause of cracking stainless steel parts
• Metallurgical evaluation of turbine casings. The evaluation of the effect of over temperature running
• Metallurgical and failure examination and lifing studies for compressor blades and rotors
• An evaluation of electro-spark deposition for repaid of blade coatings
• Repair of an Inconel 969 rotor
• Repair of gas turbine blades
• Repair of TiAl castings
• Top face penetration control welding and in-line NDT

Renewables and general

• Fitness for service assessment of hydropower plant components
• Fitness for service and failure investigation of hydroplant penstocks
• Life extension and inspection services for major pump storage plant
• Fatigue fracture mechanics analysis of pump turbine casting
• Examination of guide vane weld metal
• Analysis of cracks in Collywobbles hydroelectronic generator

Wind turbines

• A summary of constant amplitude fatigue test data for welded joints at long endurance
• Cumulative damage of welded joints. A literature survey on the influence of stress magnitude on the value of the sum of n/N
• A literature survey on the influence of a salt spray environment on the fatigue strength of welded joints
• Ultrasonic inspection of circumferential butt welds in wind turbine shafts

Fuel cells and battery storage

• Joining and sealing of solid oxide fuel cell (SOFC) components
• Development of joining technology for a polymer cell
• Development of production process for polymer energy cell (laser transmission welding)

Solar energy

• Design and manufacturing recommendations for renewable energy source

For further information, please contact us at: power@twi.co.uk