Testing, calculation and assessment of plants

Topic of the month - May 2014

© Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

SPG is an accredited inspection facility that assesses power plants and their components under statutory specifications and acknowledged directives. © Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

Growing challenges in energy efficiency mean that an industrial company can only stay competitive on the global market if it takes a suitable range of measures. One of these challenges is that a company must avoid production losses and downtimes while at the same increasing its quality and maintaining its competitive edge.

Extensive services for high-throughput plants

Siempelkamp Prüf- und Gutachter-Gesellschaft mbH – SPG for short – has had over 50 years of experience in testing high-throughput plants and in calculating the mechanical strain on individual components with special regard to the materials that are in use.

This allows detailed assessments of plants and their levels of use, with reliable conclusions about their remaining lifetimes – results that help a company to remain sustainable and competitive.

Using its key skills, testing – calculation – assessment, SPG supports customers in the energy and power plant sector as well as in the chemical and petrochemical industries, helping them to minimise production losses, reduce downtimes and increase and optimise their quality.

The roots of SPG go back to a facility called Forschungs- und Versuchsanstalt für Strömungsmaschinen (Research and Test Institute for Turbomachinery) on an industrial estate in Dresden.

This is where several material, calculation and testing departments were set up in 1956 and 1957 and where the company still has its premises the present day.
© Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

SPG has its own test lab with state-of-the-art test machines and measuring equipment. © Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

Reducing downtimes and improving efficiency

SPG is an accredited inspection facility that assesses power plants and their components under statutory specifications and acknowledged directives. While a system is down, SPG's customers are given comprehensive, highly efficient service which may also include coordination between various departments. This means that all parts of the system are tested in a way that is fast, safe and targeted.

Based on component-specific estimates of the level of wear and tear, SPG makes recommendations on lifecycle monitoring or on any necessary inspection cycles of the plants and their components.

This expertise is based on continually updated results obtained through the research that has been conducted at SPG's own fatigue and creep test facilities for over 50 years. Such a knowledge edge allows precise assessments of the long-term stability of any heat-resistant materials and their welds which are used at the plants.
© Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

© Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

Reliable calculations of plant safety and availability

Static and dynamic stability certificates and lifecycle calculations make a vital contribution to the safety and availability of machinery, equipment and pipes. This applies to both nuclear and conventional power stations and also to chemical and petrochemical plants, and it involves the use of standard regulations for mechanical, plant and power station engineering.

Varying from case to case, it also means the calculation of formulas, specially tailored software to determine the structural stability and dynamics or the finite element programs ANSYS® or ABAQUS®. For processes with highly nonlinear patterns, such as high-speed collision dynamics, SPG uses the explicit simulation program LS-DYNA®.

Calculations of this kind must always include the relevant material properties, e.g. linear-elastic, elastic-plastic and time-dependent behaviour (including creep). One way to verify the calculated results is to combine material and component tests.
© Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

Throughout the world customers benefit from SPG's many years of expertise. © Siempelkamp Prüf- und Gutachter-Gesellschaft mbH

Highest skills level through many years of expertise and collaboration on specialist teams

SPG has its own test lab with state-of-the-art test machines and measuring equipment for comprehensive destructive and non-destructive material tests, staffed by experienced teams who are certified for processes involving non-destructive tests under DIN EN ISO 9712.

There is close collaboration between SPG's Material & Component Testing Division and Plant Inspection, so that customers can be assured of maximum expertise, e.g. in the material behaviour and damage mechanisms of creep-resistant steels. The SPG expert team has 145 creep test machines among its facilities and can look back to a tradition of over five decades.

Safety, availability and economic efficiency – worldwide

As a company in the global Siempelkamp Group, SPG offers its services for plants and plant components on an international scale. Throughout the world customers from the energy and nuclear power industry and from the chemical and petrochemical industries benefit from SPG's many years of expertise and from its highly skilled and experienced workforce.

The Siempelkamp Group as a whole operates as international industrial equipment suppliers in mechanical, plant, nuclear and foundry engineering.

Its workforce of over 3,200 around the globe help to ensure that the Siempelkamp Group with its engineering services and its general approach continues to be among the top players in the world and that it works, above all, in the customer's interests.

Frank Lindner