In CW50-2010 efforts to continuous improvement and development of IMR’s welding technology culminated after several processes checks and reference annealing now in the successful and timely completion of the first “P92” weld in manual TIG/E process within the new coal fired power plant Wilhelmshaven for Electrabel Gas de France Suez with the dimensions of outer diameter 570 x wall thickness 75 [mm ]. Figure 1 shows one of our HD-welder at important measuring of the pipes inner misalignment.
After a well deserved Christmas break of our HD pipeline welders was in KW02-2011 now run the second weld of excellent quality. Figure 2 gives an impression of the welding task.
The ultrasound examinations in CW01-2011 of the first and in CW03-2011 of the second weld confirmed the standard conform welding of the welds under the supervision of our customers from Duisburg and of the Notified Body TUEV Rheinland. The UT Inspector our business partner Pockrandt, Oberhausen can be seen in Figure 3 during its audit work.
In December, 2009 the order was given to IMR for manufacturing and erection of IP, LP and partial HP piping systems of the project „New building of KW Rotterdam Electrabel EBL2 “. The customer Hitachi Power Europe GmbH (HPE) from Duisburg builds there essential components of the new 800 MW coal power plant for the belgian energy provider Electrabel.
The order contains in the main focus pipes in the machine house with e.g. HP turbine-connections for extraction steam system LBQ, as well as auxiliary system LBG and various media there and in the boiler house as well as in the media wing. Besides classical, low and higher alloyed pipes within the HP part P91 (1.4903) OD 914 x thickness 16, P92 (1.4901) OD 570 x thickness 75 and WB 36 (1.6368) OD 273 x thickness 10 are to be welded as material.
In the competition as a system supplier for assembly and welding technology of e.g. fresh steam pipes and turbine connections strives the IMR further at the head in the processing of the material X 10 CrWMoV 9-2 (material number 1.4901). The long winter was used to weld together in January 2010 pipes from the so-called “P92” material with the dimensions 330×64.
This king’s class of the high pressure-pipe line construction is the measuring pole for everybody who wants to be possible as a supplier for modern power plants. An extract from the metallurgical investigations of the test lab Herne of our partner „Germanischer Lloyd Hamburg“ is added to this article. Among the rest, the reimbursement effect is to be easily recognized in this picture very well by the clearly finer grain under the hot passed, lower E-Hand welded layers.
WHV EBL Ansicht
In December, 2009 the order was given to IMR for manufacturing and erection of IP, LP and partial HP piping systems of the project „New building of KW Wilhelmshaven Electrabel W1“. The customer Hitachi Power Europe GmbH (HPE) from Duisburg builds there essential components of the new 800 MW coal power plant for the belgian energy provider Electrabel.
The order contains in the main focus pipes in the machine house with e.g. extraction steam, as well as auxiliary systems of various media there and in the boiler house as well as in the media wing. Besides classical, low and higher alloyed pipes within the HP part P91 (1.4903) and P92 (1.4901) are to be welded as material.
October 2009: In Cooperation with Hitachi Power Europe GmbH IMR has successfully introduced different Software-Solutions from the Piping Solution of Intergraph PP&M Germany GmbH. With the help of SmartPlant Isometrics based on the ISOGEN-Standard 80 KKS within small bore piping have allready been designed.
The KKS respectively the Isometrics and the associated bill of material after *.idf import or own construction in Isometrics are available both as paper print out and as file in the formats *.pdf, *.dgn, *.pcf, *.dwg and *.pod.
The control over process engineering , material logistics resp. provisioning , welding tracking, progress controling and quality asurrance are expedited within the software PiCoDa (PipingControllingDatabase). In this database all engineering, procurement and construction relevant information of our customer and of ourselves are e.G. imported as Excel-Import and serves apart from the central supervision of these processes also as automated input for the customizable text fields of the Isometrics. Furthermore an automated documentation according to the european pressure equipment directive is provided.
The up-to-date advantages of digitalized engineering documents and the centralized management via our IT-infrastructure based on our new part HP/ part Cisco server in Hamburg and on our Network Attached Storages in the on-site LAN’s are forging ahead and are available for our customers for their engineering and controlling processes in so to speak real-time.
In May 2009 auditing of procedures Rohr 33,7×8.0mm and 396*30mm for the material X 10 CrWMoV 9-2 material- Nr. 1.4901 were tested through weld verification as well as NDT (company Pockrandt www.pockrandt-tqs.de) and through destructive testing (Germanischer Llyod Prüflabor, Herne).
In cooperation with the TÜV Nord (Western area, Essen region, www.tuev-nord.de) the Vallourec&Mannesmann basic material with BÖHLER-filler material was welded with ours Kemppi 4000 by our experienced GmbH-cooperant following instructions given by our welding expert (EWS/IWS) Mr. Ingo Meiners. Preheating, controlled and low carbon annealing (so-called „Soaking“) and stress-free annealing were carried out by the company Inpro GmbH, Mors (www.inpro-moers.de).