Intervention of renewables such as wind and solar, which can literally fall off within minutes, means that the conventional
plants have to be ready to brought back into full operation at a very short notice. This has necessitated the design and
operation of power plants to withstand damage when starting up at a very short notice. Thus in addition to creep, fatigue
has now also become a dominant factor in determining the safe operating life of existing power plants.
Risk based maintenance (RBM) is now becoming a common feature of many industries including power and process plant
as it essentially reduces the cost of inspection without reducing the risk. Similarly Reliability Centered Maintenance (RCM)
is now also finding more favor with many type of industries, including power and process industries.
Some of the above and related topics will be discussed at this meeting.
Papers/ Presentations and Meeting Proceedings: As this is primarily an industry led Technical Meeting some
industry experts may not be interested in offering full papers. In that case their presentations in PDF
format will be published in the electronic version of the Meeting Proceedings which will be provided to
the attendees within a couple of weeks of the holding of the Conference.
About the Organizers
AMCO is a highly innovative Metallurgical, Engineering Service provider and Consulting Company, offering technical
support services to clients. The company works through a corporate model of core staff and a pool of internationally
known technical experts with practical experience, background and expertise in power, petrochemical, refining, fertilizer,
oil & gas and process plant.
Our specialization is: Plant Life Assessment /Extension, Failure Investigation, Asset Integrity Management, Plant Cycling,
Crack Assessment, Risk Based Inspection/Maintenance, Probabilistic Assessment, Fitness-for-Service Assessment,
Conditional Assessment, Plan Reliability Studies, Vibration Analysis, Stress Analysis, Support and guidance in Plant
Operation and Maintenance; Advice in weld repairs; Support with Materials, Inspection and Monitoring; Corrosion and
oxidation issues, Bench-Marking, Technology Development, Finite Element Analysis with years experience around the
globe.
Session 1:
Welcome Speech
Abdullah Al-Shammari, President, AMCO Company Ltd, Saudi Arabia 0900- 0905h
Plenary Paper
1. History of the development of alloys for high temperature plant
Prof Dr Fujimitsu Masuyama, Dept. of Materials Science and Engineering, Kyushu Institute of
Technology, Japan
(Previously chief researcher, Mitsubishi Heavy Industry, Nagasaki and inventor of some of the new
generation of steels) 0920- 1010
Plenary Paper
2. Aberrant P91 steel and development cum demonstration of new NDE techniques and
methodologies for inspection, monitoring and life assessment of critical components
Dr Ahmed Shibli, Director, ETD Consulting, Surrey, United Kingdom 1040- 1130h
3. P91 and P92 material quality control from mill production through fabrication to plant
erection
Henryk Mazur, Managing Director, Mazur Energy, Poland 1130- 1200h
Keynote Paper
4. Life assessment and extension of power plant boilers and HRSGs
Dr David Robertson, Lead Metallurgist, ETD Consulting, Surrey, United Kingdom 1300- 1340h
5. Experience with dissimilar metal welding of P91 steel with low alloy steels
Alexandros Antonatos, Public Power Corporation of Greece, Greece 1340- 1410h
8. A comparison of different joining options of hybrid composite joints for better fatigue life
Dr Amjad Ali Khan, Department of Mechanical Engineering University of Hafr Al Batin,
Al-Batin, KSA 1540- 1610h
Session 3:
Plenary Paper
1. ASME P93 steel New miracle 9Cr martensitic steel
Prof Dr Fujimitsu Masuyama, Dept. of Materials Science and Engineering, Kyushu Institute of
Technology, Japan 0830- 0920h
Keynote Paper
2. Reliability Centered Maintenance (RCM) for power and process plant
Syed Nadeem Ahmed, Independent Consultant,, Doha, Qatar 0920- 1000h
3. A Case Study for Implementing Strategies to Address High Temperature Damage Issues
Stephen Newcomb, Technical Manager, SAHARA Petrochemical Plant, Jubail, Saudi Arabia
1030- 1100h
Keynote Paper
6. Assessment of cracks in industrial components according to the international codes and
procedures
Dr Ahmed Shibli, Director, ETD Consulting, Surrey, United Kingdom 1300- 1340h
Keynote Paper
9. Operational Governance to Sustain Operational Excellence (BAPCO Case Study)
Ms. Sumah Hammad, Operational Excellence Management System Leader, Bahrain Petroleum
Company (BAPCO), Manama, Bahrain 1510- 1550h
Recently there has been a concern in high temperature industry following a number of failures in P91 thick section
components (at plant operating life of as short as 20,000 hours) and in dissimilar metal welds (at plant life of only 5,000
hours or so). In the case of T91 thin section components recent findings from research and demonstration projects
(supported by limited plant experience) have shown the steam side performance of this steel not as good as originally
predicted with reports of replacement by some utilities of T91 superheater tubing after only a short service duration.
Furthermore, recent work and publications by plant manufacturers, operators and researchers have shown that, unlike
the traditional CrMoV steels, the heat treatment of P91 and P92 steels both during and after component and weld
production needs to be precise as its control and management can be critical in determining the integrity of P91 and P92
components. Successful plant operators have relied on detailed P91/P92 material understanding and component quality
checks to ensure safe and reliable operation of their plant. Similarly for welding the more successful plant manufacturers
have relied on high quality welding and have followed more promising procedures. However, unfortunately there is no
international consensus on the best procedures to use. Some international procedures/ recommended practices have
now been found not to be suitable for this steel but will continue to be followed for various reasons. Partly as a result of
this, there is new steel in the market, and old one in service that needs more careful analysis, NDE, hardness checks,
component monitoring and integrity assessment.
Moreover, in the new competitive market outsourcing has become a common practice by the manufacturers in an effort
to cut the price of new plant. But sometimes outsourcing of plant manufacturing and welding to companies and countries
with relatively less experience and unsatisfactory practices has caused, and continues to cause, problems with new plants
using this material. In the case of HRSGs this can have even more far reaching effects due to their compact nature and
thus the difficulty of access to many components for monitoring or repair. Thus the plant manufacturers, owners,
operators, service providers and inspection/ insurance/ safety authorities all need to be aware of the complexities of the
issues involved and how to recognize problems when they occur in components made from this steel e.g. vulnerable
casts, incorrect heat treatment etc. both at the purchase and at the plant operation stages.
The understanding of the basic mechanisms and characteristics of these steels will enable the plant operators and service
providers to help operate plant more efficiently and reduce forced outage periods and associated costs/ risks. It will help
them to better develop component monitoring strategies, take palliative measures in time and make informed run/ repair/
replacement decisions.
At the plant component mid-life stage, when a few of the P91 components have already shown problems/ cracking/
failures, a basic understanding of the underlying principles of this material behavior will help to develop cost effective
procedures for damage assessment and life prediction and an understanding of how life of older plant/ structures can
be extended
T R A I N I N G DAY ONE
Tuesday, 18 October 2016
08:30 Registration and Coffee
09:00 Welcoming by AMCO Team
DAY - 1
Understanding Material Properties, Microstructure, Heat
Treatment and Steam Side Oxidation of Thin Wall Tubing
Dr David Robertson
Lead Metallurgist
ETD Consulting, UK
Objective
To develop a better understanding of the underlying concepts and basis of P91 development,
its properties, the effect of heat treatment, chemical composition and understanding its weldment
behaviour.
P91/ P92 specifications, inspections and control required during manufacturing and erection
processes.
Availability of material from various sources and quality control and checks required when
purchasing and receiving material. Acceptance test of components, hardness, microstructure
etc.
The effect of heat treatment (autenitising/normalising and tempering) on microstructure and
hardness and best available practices.
The effect of heat treatment on material strength, creep strength, hardness and ductility etc.
The effect of chemical composition details and what to look for.
European, ASME and other codes, practices, recommendations, standards and their
differences.
Potential sources of materials data.
Objective
To create a better understanding of the basic principles of oxidation in steam and its effect on
tube over-heating and cracking/ failure.
T R A I N I N G DAY T W O
Education: Fujimitsu Masuyama received PhD from Osaka University, Japan.
Wednesday, 19 October 2016
08:30 Registration and Coffee
09:00 Welcoming by AMCO Team
Day - 2
Understanding Material Welding, Welded Component Behaviour and
Component Integrity / Life Assessment Issues
Objectives
To understand how P91/ P92 component integrity can be assessed. What are the available
techniques and the advantages that they may offer. This includes a better understanding of the
basic principles of oxidation in steam and its effect on tube over-heating and cracking/ failure.
Dr David Robertson
Lead Metallurgist
ETD Consulting, UK
Objective
To create an understanding of the welding and pre- and post-weld heat treatment requirements
and the criticality of the precise control required for this steel. These issues will refer to industrial
experience to date.
Specific topics will include:
Suitable welding procedures
Pre-and post-weld heat treatment and Type IV failures in thick section components.
Strength/ life reduction factors.
Effect of plant cycling on cracking type, especially Type IV cracking.
Weld repair issues.
Dissimilar metal weld issues (P91/ P92 to low CrMoV steel welding, P91/ P92 to austenitic
stainless steel welding), the effect of cycling and lessons from plant experience.
Dr Robertson has been coordinating the Group since it was formed by ETD in 2006 to better
inform international industry about the issues related to use of grade 91 steel.
Dr Robertson regularly lectures on materials, component damage, maintenance issues and life
assessment as part of ETDs training courses on Life Assessment of High Temperature Plant,
HRSG Integrity, Boiler Maintenance and new materials (P91/P92, etc). Courses have been
held in the UK, Europe, Canada, Malaysia, Middle East, Philippines and USA.
REGISTRATION Team Discounts
You can register yourself or your colleague via sending this form to Team Discounts are available, please
contact sales@amco-consult.com
sales@amco-consult.com
BOOK AND PAY BEFORE 25th September 2016 AND SAVE UP TO SAR 2000
Early Bird Price:
Payment before 25th Standard Price: Benefits
A u g u s t 2016
First Name: ... Surname ........................................ Note: Details of the sponsorship can be
shared in separate email.
Email:Telephone:
Company: Address: ..
City: . Country: .
Intercontinental Hotel
Signature: Date: .