Sickle Plate reconstruction work was carried out successfully in the penstock piping at Bifurcation Joint 2 of SLBHESSrisailam. Original Sickle Plate failed during 2008 due to various factors like Design inadequacy, operationtional imbalance, Geometric / Metallurgical Stress raisers at the inner curve of Sickle Plate. The newly constructed Sickle Plate has been put in service which has enabled the units to generate electricity to the 100% of the rated capacity.
Sickle Plate reconstruction work was carried out successfully in the penstock piping at Bifurcation Joint 2 of SLBHESSrisailam. Original Sickle Plate failed during 2008 due to various factors like Design inadequacy, operationtional imbalance, Geometric / Metallurgical Stress raisers at the inner curve of Sickle Plate. The newly constructed Sickle Plate has been put in service which has enabled the units to generate electricity to the 100% of the rated capacity.
Sickle Plate reconstruction work was carried out successfully in the penstock piping at Bifurcation Joint 2 of SLBHESSrisailam. Original Sickle Plate failed during 2008 due to various factors like Design inadequacy, operationtional imbalance, Geometric / Metallurgical Stress raisers at the inner curve of Sickle Plate. The newly constructed Sickle Plate has been put in service which has enabled the units to generate electricity to the 100% of the rated capacity.
Application of NDT Methods as Tools for Successful Reconstruction of
Sickle plate at Srisailam Left Bank Hydro Electric Project
Rama Dasu Pittala
M/s Sun-Mann Engineers & Consultants, Secunderabad-500011, India Email : sunmannec@gmail.com Keywords: Sickle Plate, Bifurcation Joint, NDT Methods, Weld Sequence, Process Control.
Abstract : For the first time in the world, Sickle Plate reconstruction work was carried out successfully in the Penstock piping at bifurcation Joint 2 of SLBHES- Srisailam, during May-July 2013. The Original Sickle Plate failed during 2008 due to various factors like Design inadequacy, Operational Imbalance, Geometric / Metallurgical Stress raisers at the inner curve of Sickle Plate, lack of side wall fusion in horizontal weld joints etc. Weld sequence has been prepared to minimize the internal stresses due to welding. Weld Procedure and Welders were qualified as per applicable Codes. NDT Methods MT,UT, RT,PT and Visual have been used at various stages including Final Inspection to ensure the integrity of construction as per Specifications. Detailed Ultrasonic Examination and Magnetic Particle Examination of remaining portion of failed sickle plate was carried out , prior to commencement of reconstruction. Plates used for preparing sickle plate segments were tested for presence of laminations before cutting. Gas-cut and ground edges were tested by Magnetic Particles for ensuring freedom from open to surface / sub surface flaws. During welding in addition to strict process control ( including preheat, current, speed, cleanliness at each pass, start stop points control, post heating temperature control etc), visual and dry magnetic particle testing carried out to ensure freedom from flaws. Final NDT carried out using NDT methods RT,MT,UT, VT and ensured that the newly constructed sickle plate is free from un acceptable flaws. The newly Constructed plate has been put in to service which has enabled the Units to generate electricity to the 100% of the rated capacity. Introduction : Bifurcation Joints are required to divide flow in a penstock to feed multiple units. Plan, Elevation and Isometric view showing typical bifurcations is shown in Fig.1 At the bifurcations Internal sickle plates and external yokes are constructed to strengthen the structural members and counter the unbalanced forces created by the flow. Location and construction details of Sickle Plate are given in Figs. 2 & 3..
Fig.1[2] Plan, Elevation and Isometric View of Bifurcations Fig.2 [2] Location & Construction details of Sickle Plate - Plan Fig.3 [2] Location & Construction details of Sickle Plate - Elevation
The Failure : On 11 th Oct 2008 around 6.00Am, heavy vibrations were observed in Unit 2 during service. Draft tube was emptied and on 19 th Nov 2008 and when examined inside, part of Sickle-plate at bifurcation between Units 2 & 3 was found stuck-up in the spiral casing of Unit 2 ( ref.Fig.4). Another broken part was found in the Penstock at Pressure shaft 1 sump . Remaining portion of sickle plate at the bottom position is shown in Fig.5. Schematic diagram showing fracture profile is given in Fig.6
APGENCO constituted expert committee comprising experts from CWC, IIT-Delhi, L&T + MWH USA, APGENCO, NML, CEA, WRI-BHEL Trichy, FCRI-Palghat to look in the problem, examine the causes of failure of Sickle Plates and suggest remedial / rectification measures. Remedial measures: As suggested by the expert committee, the fractured surface of remaining portion of buried sickle plate was smoothened by Cutting / Grinding and weld metal deposition. The Units 2 & 3 were permitted to operate in Generation mode at a Geometric Stress raiser at Inner Curve ACEGI : Part of Sickle Plate found in Spiral casing of Unit 2 BDFH : Part of Sickle Plate found in Pressure Shaft 1 Sump Fig.4[1] Part of Sickle Plate found in Spiral casing of Unit 2 Fig.5[1] Remaining Part of Sickle Plate at the bottom position. Fig.6 . Failed Sickle Plate at Bifurcation between Units 2 & 3 capacity not exceeding 75% with a condition both the units must be in operation. If one unit stops, the other unit also must be stopped. Root cause of failure: The committee could not come to any definite conclusion regarding the root cause of failure. Design inadequacy, Operational Imbalance, Geometric / Metallurgical Stress raisers at the inner curve of Sickle Plate, presence of Lack of Side wall fusion of Longitudinal Weld etc. might have contributed for the failure. However in the opinion of the Author the most probable failure scenario may be as follows. A) Due to presence of Geometric and metallurgical stress concentrations in the inner curve, crack initiation has occurred in the horizontal weld joint, which has propagated till the outer curve, aided by the presence of lack of side wall fusion in the longitudinal weld [1] and differential pressures on the both the surfaces of sickle plate [2]. B) Subsequently due to the differential pressures on both the surfaces the sickle plate segments might have been subjected to repetitive bending cycles resulting in the separation by fracture of parent metal due to fatigue. New Design : Based on various studies and deliberations by the expert committee, M/s MWH-USA has given a new design of sickle plate as per Fig. 7. Free End patch-plates, Patch plates to join Sickle Plate to Ferrule were included in the new design to meet the design requirements. The Author attended 19 th and 20 th Expert committee meetings on behalf of APGENCo and proposed location of weld joints and sequence of welding. The weld joint locations were chosen in such a way that there is minimum amount of welding and the Hot rolled plates are used in proper direction with respect to the direction of rolling, and for the patch plates there is overlap between similar welds located in the opposite faces (ref.Fig.8). The Weld sequence was prepared to minimize residual stresses and distortion (ref.Fig.9).
Fig.7 New Design of Sickle Plate Provided by M/s MHW - USA
Fig.8 [3] Location of Weld Joints, Shown in Red-Vertical and Blue Fig.9 [3] Weld Sequence, Shown in Roman Numerals Methodology: Detailed Methodology has been prepared and implemented to ensure that the Reconstruction of Sickle plate confirms to the project technical specifications / codes ( Ref. Diagram-10). DIAGRAM.10 METHODOLOGY
Process Control: Welding Process was controlled and monitored by deploying Welding Inspectors on 24 X 7 basis during the project execution. Ensuring deployment of Qualified Welders for applicable Welding Position, Electrodes Control (including storage, baking, handling and usage), Preheat, Welding Current, Electrode Travel Speed, bead width, inter- Approval of Drawings as per MWH recommendations, Qualification of Welders and WPS, preparation of Final WPS,PQR and WPQ, Approval of NDT procedures, Weld sequence Fit-up of part Nos 1 & 2 and welding and post heating as per Qualified WPS / sequence Fit-up of part Nos 3 & 4 and welding and post heating as per Qualified WPS / sequence
Process Control including preheating and post heating, In-process visual , NDT and distortion measurement
Final visual, UT,MT &RT of new Sickle plate welded joints, before patch-plates fit-up
UT & MT of plates to ensure freedom from laminations at the cut and ground edges
Tracing of profile by templates for preparation of patch plates components UT & MT of plates to ensure freedom from laminations at the cut and ground edges of patch plate components
Verification of Material TCs. Electrode TCs, Tracing of profile at the remaining portion of failed sickle plate using templates and marking for cutting UT and MT on remaining portion of failed Sickle plate at bifurcation 2. Process Control including preheating and post heating, In-process visual , NDT and distortion measurement Repair of cracks appeared on ferrule weld joints, and ferrule to old sickle plate weld joints, as per MWH reviewed repair procedure Qualification of modified WPS-4, preparation of PQR for welding of patch- plates Fit-up of patch plate components, welding and post heating as per modified / Qualified WPS / weld sequence
Process Control including preheating and post heating, In-process visual and NDT
Final visual, UT,MT of patch plate welded joints before painting
pass cleaning, MT/Visual examination for each layer of welding, Post heating, Humidity data logging etc. are some of the important parameters that were monitored to ensure compliance to the approved and Qualified WPS.
NDT Scheme followed : 1) Prior to welding, MT & UT of remaining portion of sickle plate and weld joints performed as per approved NDT procedures.(ref. Figs .11 & 12). For MT wet visible particles with white contrast were used in combination with Half-wave DC Yoke. For UT, 4MHz 20 Dia TR probe, 4 MHz 45 8X9 size, and 4 MHz 60 8X9 size probes were used. Calibration blocks used for UT was made as per ASME Sec V Article 4, Fig.T-434.2.1 Non Piping Calibration Block. The findings indicated that there are no un-acceptable flaws.
2) The Hot rolled plates of ASTM 517 Gr F material was tested and certified by steel mill to SA 578 Level C, which permits lamination up to 25mm dia. Hence to rule out the possibility of any lamination opening on the weld edge, 100mm wide scanning performed covering both sides of cutting plane, after marking. 6mm FBH was used as reflector for calibration, and 4MHz 25mm dia TR probe was used for scanning.
3) During welding after each layer and back grinding also MT was performed using Dry Visible Particles in combination with Half-wave DC Yoke. Relevant Indications found were removed before next layer is welded.
4) After 72 Hrs of completion of welding and post heating, final NDT (VT,MT UT &RT) performed on new sickle plate weld joints. For MT wet visible particles with white contrast were used in combination with Half-wave DC Yoke. For UT, 4MHz 20 Dia TR probe, 4 MHz 45 8X9 size, and 4 MHz 60 8X9 size probes were used. Calibration blocks used for UT was made as per ASME Sec V Article 4, Fig.T-434.2.1. Radiography performed using Ir 192 source with single wall single image composite film viewing technique. In UT and RT, one un-acceptable linear indication of about 6mm long was found in Vertical weld ii at around 850mm from bottom. The same was repaired as per qualified WPS and repeat NDT (MT,UT & RT) performed to ensure soundness of the weld.( ref.Fig.13). UT being performed on Vertical weld V is shown in Fig.13
5) During MT, cracks were found in the weld joint between remaining old sickle plate and ferrule, and also in weld metal of ferrule to ferrule near T joints. Apparently these cracks appeared due to differential expansion of remaining old sickle plate and ferrule during Fig.11- MT of Remaining Sickle Plate before welding new Sickle Plate. Fig.12- UT of Remaining Sickle Plate / adjacent Old Weld Joints. preheating / post heating. All the cracks were repaired as per MWH reviewed procedure and NDT (MT / PT ) performed to ensure soundness.
6) Subsequently Welding of Free End patch plates and Sickle plate to Ferrule patch plates carried out as per approved and qualified WPS. In process MT carried out as indicated in Point-1 and ensured soundness of each layer. 7) After 72 Hrs of completion of welding and post heating, final NDT(VT,MT&PT) performed on the new sickle plate to patch-plate weld joints. For MT wet visible particles with white contrast were used in combination with Half-wave DC Yoke. For UT, 4MHz 20 Dia TR probe, 4 MHz 45 8X9 size, and 4 MHz 60 8X9 size probes were used. Calibration blocks used for UT was made as per ASME Sec V Article 4, Fig.T-434.2.1. No flaws were found. Weld Visual Test confirmed that the weld profile / size is satisfactory.
Conclusions: Using NDT Methods as tools at various stages in combination with strict Process Control during welding, reconstruction of Sickle Plate at Bifurcation Joint No.2 of SLBHES Srisailam has been completed meeting the Quality Requirements of the Project. The Units have been put in to service at 100% of the rated capacity since August 2013. For the first time in the world such a difficult and complex job of constructing Sickle Plate in situ has been completed successfully. Balanced operation of Units and Periodical Condition assessment during off season has been recommended to maintain the structural integrity of the new sickle plate.
Acknowledgements: The Author acknowledge the useful discussions held with Expert Committee Members and support of M/s APGENCO in successful completion of the project.
References [1] S.R.Singh, National Metallurgical Laboratory-Jamshedpur, Failure Analysis of Penstock Liner Sickle Plate of SLBHES-Srisailam, report No.NML/MST/APGENCO/2009 [2] J.Chandrasekhar Iyer, Rakesh Toteja, CWC-New Delhi, Power point Presentation on Engineering Failure Analysis to find out the Cause and Evolve a Solution - A Case of Penstock Bifurcation Sickle Plate Failure at SLBHE- Srisailam , 2013. [3] Rama Dasu Pittala, Sreedhar Mallipudi, Sun-Mann Engineers & Consultants,-Secunderabad, India, Report on Reconstruction of Sickle Plate at Bifurcation Joint No.2 at SLBHES-Srisailam, 2013. [4] ASME Boiler and Pressure Vessel Code Section V & VIII Div-1, 2011a [5] AWS D 1.1-2010, Structural Welding Code-Steel. [6] Dr.Kohsuke Horikawa- Osaka University, Nomozu Watanabe- NPSICL/MHIL, Japan , Application of High Tensile Strength Steels for Hydro Power Plants - 2009 Fig.13: UT of Vertical weld joint of New Sickle Plate.