Smart Inspection & Monitoring
Extension of inspection intervals and remaining service life assessment using SIM and the xHalePlus online system
Request advice on SIM and xHalePlus
Extension of inspection intervals and remaining service life assessment using SIM and the xHalePlus online system
Request advice on SIM and xHalePlusPower station and plant components such as pipework, valves and boilers are often subject to severe wear caused by thermal cycling. These stresses can cause micro-cracks in the material, which develop into technical cracks over the course of the component’s service life.
Normally, the service life of the affected component then comes to an end as a result of premature repair work or replacement, even though its potential remaining service life has not yet been exhausted. Alternatively, relevant cracks are detected too late. This results in unnecessary downtime and repair costs.
Smart Inspection & Monitoring, or SIM for short, is DMT’s comprehensive digital concept for assessing the service life, integrity and inspection intervals of plant and plant components.
SIM combines fracture mechanics-based damage tolerance analyses, engineering services, online monitoring via xHalePlus and regulatory compliance aspects into an integrated solution. Based on operational data and sound engineering expertise, we establish the basis for assessing inspection intervals in a technically verifiable and regulatory-compliant manner.
This enables us to tap into untapped service life potential, plan maintenance measures proactively and reduce unplanned downtime. In doing so, we consistently keep safety, plant integrity and the requirements of relevant regulations firmly in mind.
Michael Schneider
Sales Monitoring
+49 160 8884392
An online system for determining the remaining service life of power station and plant components subjected to alternating loads. xHalePlus provides load data at specific time intervals and calculates the progression of potential cracks step by step.
It can be
used as a data basis for extending inspection intervals or independently to optimise plant operation.
Maintenance costs are becoming easier to manage.
Permissible inspection intervals can be calculated online, and forecasts can be generated based on the plant’s operating mode.
Maintenance costs are becoming easier to manage.
Permissible inspection intervals can be calculated online, and forecasts can be generated based on the plant’s operating mode.
Use SIM to unlock the untapped service life potential of your plant components without having to replace them prematurely.
Fewer operational disruptions, lower maintenance costs and improved efficiency of your plant.
The concept is suitable for plant operators, inspectors and component manufacturers who deal with the challenges posed by components subject to alternating loads – across many energy sectors and industrial sectors with comparable process parameters. It is based on the online monitoring of structural-static, structural-dynamic and vibro-acoustic data.
Please contact our experts to find out more about our solution and to develop a bespoke strategy tailored to your requirements.
Fracture mechanics-based damage tolerance analysis has already been incorporated into relevant standards as a recognised method for assessing integrity and determining inspection intervals, including:
Smart Inspection & Monitoring, or SIM for short, is DMT’s comprehensive digital concept for assessing the service life, integrity and inspection intervals of plant and plant components. SIM combines fracture mechanics-based damage tolerance analyses, engineering services, online monitoring and regulatory compliance aspects into a single integrated solution.
xHalePlus is DMT’s online system, which records load data during operation and continuously calculates crack growth. Within SIM, it provides the data basis for fracture mechanics analysis and the extension of inspection intervals.
SIM provides a sound technical basis for assessing the permissible inspection intervals for plant components. To this end, we analyse operational data, loads and potential damage mechanisms. On this basis, service life potential can be assessed transparently and maintenance measures planned in line with actual requirements.
A technically sound extension of inspection intervals can reduce unplanned downtime, make it easier to plan maintenance work and improve the availability of plant. At the same time, it promotes the efficient use of existing components and can help avoid premature investment.
SIM is particularly suitable for plant components subjected to cyclic loading as well as pressure and temperature. These include, amongst others, steam boilers, pressure vessels, pipework, pumps, compressors, valves, furnaces, coking drums and heat exchangers. Applications in power generation, the chemical and pharmaceutical industries, and in thermal storage systems can also be assessed.
Depending on the application, we analyse structural static, structural dynamic and vibroacoustic data, as well as relevant operating parameters. These may include, for example, pressure, temperature, load cycles, vibrations and operating modes. The data forms the basis for a reliable assessment of the plant’s condition and remaining service life.
Fracture mechanics-based damage tolerance analysis assesses how existing or potential damage in a component may develop under real-world operational loads. It helps to identify critical conditions at an early stage and to make a well-founded assessment of the remaining service life.
Yes. SIM supports the rules-based assessment of plant integrity, condition monitoring and inspection intervals. Depending on the specific application, we take into account relevant standards, technical regulations and the requirements of the competent authorities. The specific assessment and coordination are always carried out on a project-by-project basis.
No. Online monitoring does not replace mandatory inspections. It complements condition monitoring by providing continuous operational data and can serve as a technical basis for assessing inspection intervals and maintenance strategies.
It is essential to have sufficient information on plant components, operating modes, loads and previous tests. Depending on the initial situation, existing operational data can be utilised or additional measurement systems can be integrated. DMT assesses the technical requirements in consultation with you and develops a suitable approach based on this.
