Optimization of thermal–flow systems in industrial and utility power plants

In addition to traditional measurement-based methods for identifying equipment operating conditions, we also possess extensive capabilities for computer modeling of systems, thermal cycles and district heating sections.
For this purpose, we use the best available software solutions and, when necessary, develop our own dedicated applications.

The technical possibilities of modeling are virtually unlimited and include:

• power plants with steam and gas turbines,

• unit-based systems and header-based systems,

• design and off-design operating conditions,

• district heating systems,

• heating plants, boiler houses, etc.

Technical condition assessment of turbines

We perform expert assessments to evaluate the remaining service life of machines as well as their technical condition after long periods of operation and after failures. We analyze the causes of damage and assess the possibility of restarting turbines with existing defects, such as incomplete blading. We also define the scope of overhaul and refurbishment works.

In the assessment of technical condition and during modernization works, we use software from leading global suppliers, enabling:

• strength and dynamic analyses of power engineering equipment components,

• modeling of turbine unit operating conditions before and after modernization in order to determine the resulting effects,

• modeling of cooperation between multiple turbines and power equipment within a power plant to determine optimal operating conditions,

• other analyses related to steam turbines, gas turbines and power engineering equipment, according to Client requirements.

We conduct specialized turbine unit tests, such as measurements of temperature distribution in the flow path and turbine casings, thermal–flow measurements of condensers and district heating heat exchangers, testing of turbine foundation deformations (including shaft line alignment correction), and endoscopic inspections.
We also perform mechanical service inspections of gas turbines, including borescope inspections.

Technical condition assessment of steam pipelines

Ensuring long-term, safe operation of steam pipelines requires systematic monitoring of their technical condition. Such monitoring allows assessment of the degree of component wear and development of appropriate recommendations for repair or replacement of elements at risk of damage, and—where necessary—implementation of modernization measures.

Typical diagnostic testing usually includes:

• visual inspection of suspension systems and pipeline surfaces (including endoscopic inspections),

• magnetic testing of welds and external surfaces of pipe bends,

• examination of material structure on external surfaces of bends or fittings using the replica method,

• hardness testing of material at selected locations,

• measurements of diameter deformation and ovalization of bends,

• wall thickness measurements and internal surface crack assessment (ultrasonic testing),

• strain-gauge stress measurements.

The above set of tests generally allows reliable assessment of the technical condition of pipeline materials and enables planning of ongoing repairs and component replacements, provided that such inspections are carried out systematically.

In specific cases, the above set of tests may be extended to include:

• geodetic surveys of pipeline position and displacement,

• testing of forces and stresses occurring in individual components.

We offer the full scope of the above tests, tailored to the Client’s requirements.
We also provide preparation of as-built (reverse-engineering) pipeline documentation for the purposes of IDT.