News and Views, Volume 54 | Structural Integrity Supports Pipeline Research Council International’s Hard Spot Project

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By Scott Riccardella and Steven Osgood

Structural Integrity is pleased to be working with PRCI to improve ILI performance, provide industry insight regarding prioritizing hard spots, and determine the optimal repair methodologies.

SI’s Pipeline Integrity Compliance Solutions (PICS) group has been implementing a highly strategic project from the Pipeline Research Council International (PRCI) focused on enhancing industry capabilities to detect and assess hard spot anomalies in gas transmission and hazardous liquid pipelines.

PRCI reviewed proposals from several highly qualified firms to support this project. Ultimately, SI was selected to provide support based on a combination of our expertise and integrated proposal, which demonstrated capabilities in field assessment, engineering analysis, and a reputation for providing synchronized follow-up. Being part of this PRCI project reinforces SI’s dedication to helping improve pipeline integrity and assessment practices and further position SI as an expert consulting partner for supporting pipeline operators’ fracture mechanics and in-line inspection (ILI) needs.

About the Project
Hard spots, or localized areas with elevated hardness within the pipe body, were believed to form during manufacturing. Hard spots are prevalent in piping produced by certain manufacturers and/or within certain vintages. They are believed to be attributed to inadequate quality control in the steelmaking, pipe-rolling, and welding processes. Over time, when in specific environmental conditions, cracking can initiate in the hard spots, creating a significant hazard. PRCI issued an RFP focused on evaluating and enhancing ILI tool technology and complementary analytical capabilities to reliably detect, size, and characterize the threat to integrity caused by hard spots.

Project Objective and Details
The project objective is to help the industry better understand ILI performance for more accurate detection and characterization of hard spots, providing targeted feedback, and developing insights to help improve ILI performance and prioritize ILI results.

ILI Performance Evaluation Study
The project’s main task is to evaluate the performance of various ILI technologies and service providers in identifying and characterizing hard spot defects. Testing is performed at the PRCI Technology Development Center (TDC) with pipeline samples (with various hard spot features) removed from service and configured in a test string for pull-through testing from several participating service providers. SI has characterized these samples using advanced NDE methodologies to establish reference data that will be used for determining the probability of detection (POD), probability of identification (POI), sizing accuracy, hardness estimation accuracy, and location accuracy. Individual performance reports will be provided as feedback to the participating ILI service providers to facilitate improving and advancing ILI technologies for hard spot detection and characterization.

Developing the Repair/Response Criteria
Following this testing, SI will complete additional analysis and modeling of the ILI Reported Values versus measured dimensions and hardness values for associated error. SI will also perform modeling to develop statistical correlations (with associated uncertainties) for estimating the Peak Hardness & Hard Spot Length from ILI Reported Values. Data will be analyzed in the context of historical failures and regulatory definitions of a hard spot. SI will develop an assessment methodology to evaluate hard spot criticality with a recommended response criterion (feature prioritization scheme) based on feature severity (length, hardness) and relative safety margin (Predicted Failure Pressure / MAOP).

“This project helps advance a critical initiative for PRCI, helping improve ILI capabilities to address a key threat to pipeline integrity. We are grateful to be partnering with Structural Integrity to develop and deploy this knowledge to our members.”

Jim Wayman – Program Manager Integrity and Inspection – PRCI

Evaluation & Recommendation of the Repair Methodology
SI is also working to complete research on different material properties and repair methodologies to determine the suitability of repairs. As part of this task, SI will complete a benchtop study using finite element analysis (FEA) to study the effectiveness of each repair approach (composites and Type A sleeves) leveraging the fitness for service (FFS) methodology detailed in the prior task (Repair/Response Criteria).

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Structural Integrity Associates Acquired by MidOcean Partners

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SAN JOSE, CA – August 15, 2024 – SI Solutions today announced their acquisition by MidOcean Partners.  The transaction includes SI Solutions and all its affiliate companies: Structural Integrity Associates, C2C Technical Services, and SC Solutions.  The full press release with additional details follows below.

NEW YORK – August 15, 2024 – MidOcean Partners (“MidOcean”), a premier New York-based alternative asset manager specializing in middle-market private equity, structured capital, and alternative credit investments, today announced the acquisition of SI Solutions (“SI” or the “Company”), a leading provider of engineering, testing, inspection, compliance and maintenance services, digital solutions, and expert consulting for power and critical infrastructure end markets. Terms of the transaction were not disclosed.

With more than 450 employees, SI provides technical expertise and services to enable the reliability and resiliency of the U.S. power markets, safety and regulatory compliance of critical assets, and continued expansion of public and private infrastructure in the U.S. and abroad. The Company will continue to be led by Chief Executive Officer Mark Marano, who previously served as COO of Westinghouse Electrical Company and has deep operating experience in the utility and critical infrastructure markets. In connection with the acquisition, SI’s management team, employee shareholders, and prior investor Jumana Capital have reinvested in the business.

Elias Dokas, Managing Director at MidOcean, said, “SI is a proven industry leader with a stellar track record of serving the power and critical infrastructure markets and delivering superior engineering and specialty services to its clients. The Company has experienced tremendous growth to date and we see numerous opportunities for further growth through organic initiatives and strategic acquisitions, including expanding its service offerings and entering new markets. We look forward to working closely with the SI leadership team to deepen the Company’s relationships with its existing clients and build its market position.”

Brian Finnie, Principal at MidOcean, added, “We are thrilled to be partnering with SI. We believe the combination of SI’s expertise and longstanding client relationships with MidOcean’s utility and infrastructure services experience and dedicated team of operating experts will position the Company for continued growth and success.”

Mr. Marano concluded, “This partnership with MidOcean is the next step in the evolution of the SI Solutions platform, and I’m excited about the future of the company.  We will continue our mission to power the future of critical infrastructure, leveraging our highly skilled employees and our drive for innovation to deliver unparalleled value to our clients.  MidOcean provides us with the additional capabilities and experience to further our mutual goals to serve our industries.”

The acquisition of SI marks MidOcean’s fourth investment in the engineering and critical infrastructure sector. MidOcean previously invested in, and has since successfully exited, System One and The Planet Group. The firm also recently announced a preferred equity investment through its structured capital initiative in GridHawk Holdings, a premier provider of damage prevention services for critical utility infrastructure across the U.S.

MidOcean was represented in the transaction by Gibson, Dunn & Crutcher LLP as legal advisor. Stifel, Nicolaus & Company, Inc. served as exclusive financial advisor to SI. Locke Lord LLP acted as legal advisor to SI and Jumana Capital.

About MidOcean Partners
MidOcean Partners is a premier New York-based alternative asset manager specializing in middle-market private equity, structured capital, and alternative credit investments. Since its inception in 2003, MidOcean Private Equity has targeted investments in high-quality middle-market companies in the consumer and business services sectors. MidOcean Credit Partners was launched in 2009 and currently manages a series of alternative credit strategies, collateralized loan obligations (CLOs), and customized separately managed accounts. For more information, please visit: https://www.midoceanpartners.com/

MidOcean Investor Relations Contact:
Investorrelations@midoceanpartners.com

MidOcean Media:
Amanda Shpiner/Grace Cartwright
Gasthalter & Co.
(212) 257-4170
midocean@gasthalter.com

About SI Solutions
SI Solutions provides technical expertise and services to enable the reliability and resiliency of power markets, safety and regulatory compliance of critical assets, and continued expansion of public and private infrastructure in the U.S. and abroad.  The company is a leading provider of engineering, testing, inspection, compliance and maintenance services, digital solutions, and other consulting and advisement activities. For more information, please visit: https://www.sisolutions.com/

Media Contact:
Christopher Sydor
SI Solutions
704-977-1361
info@sisolutions.com

 

News and Views, Volume 54 | Combustion Turbine Compressor Hygiene, Part 2

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Figure 1. Lower compressor casing after large forward blade liberation, causing a forced outage and catastrophic damage to aft components.

COMPONENT ASSESSMENT AND ANALYSIS

By John Molloy

Structural Integrity (SI) has decades of experience dealing with compressor degradation’s short-term and long-term effects, forced outages, and unforeseen costs regarding Combustion Turbine (CT) compressor hygiene. The inlet package and compressor condition can strongly influence unit performance, efficiency, reliability, risk, and maintenance costs.  Controlling what enters the inlet and mitigating the effects of accumulated foreign material can significantly impact O&M activities and costs.

Additionally, in the new paradigm of cyclical operation and potentially longer downtime between operational periods, additional considerations and actions are incumbent upon O&M to prevent irreversible damage to various CT flow path components (compressor, rotor, etc).

In the 51st edition of News & Views, we discussed the CT compressor hygiene regarding component longevity. This follow-up article will dive into the assessments and analyses.

SI is pleased to offer a comprehensive suite of inspections, analyses, and O&M recommendations to help mitigate these debits to reliable, profitable, and safe operation.

Figure 2. Forward compressor blades with corrosion pitting on the leading edge, platform radius, providing nucleation sites for corrosion fatigue and cracking.

Inlet Package and Forward Compressor Detailed Site Survey

The inlet package and forward compressor site survey is a detailed visual inspection of the inlet filter house/inlet ducting assembly. The inspection allows for documenting potential sources of foreign objects, evidence of sealing issues (floor/wall/roof construction, penetrations, and filter seating), pooling water, corrosion, cracks, cleanliness, and contaminant/debris presence.

The in-depth inspection also examines:

  • Water injection/misting systems for leaks/contaminant accumulation
  • Bearing region and compressor leak entry passages for contaminants/debris
  • Pre-filter deposits/debris collection to determine local environmental loading conditions and corrodents

Figure 3. Pitting on compressor blade.

The SI team additionally collects Inlet Guide Vane (IGV) and forward blade, stator vane, rotor, and carrier deposits/residues to establish the presence of contaminants and or corrodents on the compressor, and compares this to the finding in the pre-filters to establish the efficacy of the filtration system. Particular attention is given to the compressor’s lower half, which is usually the area most affected. Photographic documentation of the typical forward compressor (IGV/R0/S0/R1) pitting conditions is completed using a macro lens (Figure 3). In the final step of the survey, the team performs a mold replication on typical pitting and leading edge (LE) erosion.

Data Collection, Analysis, and Review

Figure 4. Leading edge chloride pitting and fracture on a vane.

During the compressor hygiene testing and analyses, there are several areas where data can be collected. This includes ambient and unit flow path humidity trends, ambient and CT inlet temperature/dewpoint, water injection operation, compressor performance, and an annual borescope inspection.

Other data elements potentially collected or reviewed include water wash frequency, duration, and water wash quality checks consisting of pH and chemistry constituents review of the demineralized water source, water wash solution, and drain. In addition, the IGV calibration report, pollution, contaminant producers, and environmental wind condition survey (drift) can be reviewed if the previous findings merit this effort. Finally, the team correlates the observed pitting locations with known risk profiles for blade/vane excitation. Nodal response stresses can be evaluated for a more detailed assessment.

Laboratory Support

Figure 5. Metallographic cross-section shows leading edge erosion channeling morphology on a forward compressor blade, which facilitates fatigue crack initiation.

SI’s world-class laboratory is leveraged to provide tailored analyses for compressor assessments.

This generally includes:

  • Inlet prefilter contaminant/debris species analysis
  • IGV/R0/S0/R1/Wheel/Case surface contamination species analysis
  • Pitting and/or erosion depth assessment

Blade and vane metallurgical evaluation
When parts are available for analysis, the laboratory analyses can provide specific damage mechanisms affecting the components, which allows for better decisions on mitigation strategies. The goal of the assessment and analysis is to close the loop between the on-site unit findings, the operational assessments, to provde the client with best-in-class combustion turbine availability, and performance.

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