Overview
When conventional design and construction codes or specifications do not cover certain aspects of design, construction, or operation, an alternative approach becomes necessary. Integrity Assess Solutions offers Engineering Critical Assessment (ECA) services based on fracture mechanics, enabling engineers to validate the safety of structures or components and mitigate the risk of failure in engineering projects.
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From the design phase through construction to operation, Integrity Assess Solutions applies ECA techniques to a diverse array of welded structures. Our comprehensive consultancy and analysis services assess defect tolerance for plastic collapse, fracture, and fatigue damages in safety-critical parts of welded structures and components such as pipelines, pressure vessels, drilling rigs, platforms, and wind turbines, operating under various challenging environmental and operational conditions.
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In addition to conventional testing based on recognized standards, ECA incorporates additional criteria in the evaluation process. These include considerations such as the properties of the defect (size, location, orientation), mechanical loads (cyclic and static loads), and environmental conditions (direction, strength, temperature) surrounding the flaw, as well as material properties (toughness, tensile strength) near the defect.
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Taking these factors into account often leads to higher defect tolerances than those assessed individually. This approach helps minimise costs and time associated with unnecessary repairs and aids in preventing potential failures.
What is an Engineering Critical Assessment (ECA)?
Have more questions? If you seek further clarification on ECA or require additionalinformation, don't hesitate to reach out to our experts today.
How can we assist you with this assessment, and what advantages does it offer? Our team of specialists can enhance your understanding of ECA and its benefits by addressing common inquiries. Read the answers from one of our experts, Dr Paul Sukpe from some of the questions you might have.
What is an ECA?
An Engineering Critical Assessment (ECA) forms part of the Fitness-For-Service (FFS) approach, which evaluates flaws within structures to assess their impact on structural integrity. Flaws encompass any form of notch, void, or crack, where principles of fracture mechanics and fatigue come into play.
Who can use an ECA?
ECA can be applied by professionals involved in design, manufacturing, construction, and welding, adhering to standard codes. It ensures integrity through testing to demonstrate
compliance with minimum criteria. ECA is utilised across various engineering sectors throughout the project lifecycle, from design through operation.
Is ECA conducted in accordance with established standards?
There are recognized standards delineating ECA methodology and procedures, rooted in fracture mechanics and fatigue principles, endorsed internationally. Notably, BS 7910 and API 579 serve as reference standards, with API 1104 Annex A, DNVGL-RP-F108, offering more specialised criteria for weld flaw analysis in pipeline manufacturing.
Can you provide examples illustrating ECA applications?
ECA justifies continued service and residual life in structures with identified flaws. It also aids failure investigations, facilitating a deeper understanding of failure mechanisms and informing future improvements. Moreover, ECA supports a lean manufacturing approach,
replacing arbitrary workmanship criteria in welds with bespoke flaw acceptance criteria.
ECA is frequently employed to obtain a Post Weld Heat Treatment (PWHT) Waiver. According to ASME Boiler Codes, for wall thicknesses exceeding 1 ¼ inches (approximately 32mm), PWHT is mandatory. Nevertheless, conducting an ECA allows for an assessment of whether PWHT would yield any tangible benefits. In other words, it helps determine whether the structure meets acceptability criteria even in the absence of PWHT.
What are the advantages of conducting an ECA?
ECA, aligned with the FFS philosophy, verifies structural integrity, supporting continued service and extending asset life. It also optimises manufacturing processes, eliminating unnecessary procedures like post-weld heat treatment and repair welding, thereby reducing costs and project timelines without compromising asset integrity.
The Integrity Assess Solutions advantage.
Integrity Assess Solutions offers ECA services grounded in fracture mechanics, enabling engineers to validate structural safety and minimise failure risks in engineering projects.
Additionally, we employ Finite Element Analysis (FEA) to devise cost-effective inspection and repair plans across all project phases.