High-Energy Piping Laser Cleaning
Precision Laser Cleaning (PLC) was engaged to undertake laser cleaning during a major power station outage. The objective was to prepare surfaces for inspection processes, including Non-Destructive Testing (NDT), Magnetic Particle Inspection (MPI), and Ultrasonic Testing (UT). This project outlines PLC's innovative application of laser cleaning technology to meet stringent inspection requirements, ensuring efficient and effective surface preparation during strict outage schedules.
The Challenges
The project presented several challenges that required innovative solutions:
Dust Control: Ensuring minimal airborne contamination during cleaning operations.
In-Situ Operations: Conducting precise cleaning on-site without the need for dismantling components.
Coordination with Other Trades: Working seamlessly around other crews operating in the same outage environment.
Time Constraints: Adhering to strict outage schedules to minimise downtime.
Material Preservation: Preventing material degradation or loss during surface preparation.
The Solution
PLC deployed advanced laser cleaning technology tailored to meet the specific requirements of the project.
Key elements of the solution included:
Pulsed Laser Cleaning Technology: Offering precision and control, ideal for delicate welds and critical piping.
Multiple Laser Systems: A fleet of five laser systems were utilised to handle various inspection needs.
Portable Needle Systems: The 300W Netalux Needle systems were deployed to prepare weld surfaces for ultrasonic testing during inlet and outlet header inspections, achieving the required white metal finish.
Industrial Jango Systems: The Netalux Jango 1000W systems were deployed to clean main steam lines, CMV, and hot reheat lines in preparation for MPI inspections, where fast production speed and surface corrosion removal were the main requirements.
Continuous Operations: 24 operations over 3 weeks to meet tight deadlines.
Specialised Team: A dedicated team of 12 laser technicians worked in shifts to ensure seamless operations and optimal efficiency.
The Outcomes
PLC's innovative approach delivered significant advantages and outcomes:
Incident-Free Execution: No injuries or safety incidents were reported, particularly eliminating the risk of eye injuries associated with abrasive dust.
Extensive Coverage: Successfully cleaned approximately 2,000 welds to inspection-ready standards within a relatively short period of time.
Simultaneous Operations: Laser cleaning eliminated the need for large exclusion zones and encapsulation that are typically required for traditional abrasive blasting. This enabled inspections and other trades to work concurrently, enhancing the safety and efficiency of the outage.
Customer Satisfaction: The streamlined setup and operational efficiency of laser cleaning provided clear advantages over traditional methods, delivering time savings and enhancing safety outcomes.
Meet stringent inspection requirements during major outages
This project demonstrates PLC's dedication to innovation and safety in industrial cleaning. By utilising advanced laser technology, PLC delivered a safer, more efficient, and sustainable solution that surpassed customer expectations. The success of this project underscores the transformative potential of laser cleaning in critical industrial maintenance shutdowns.