21 April 2012

HIGH ENERGY PIPING INSPECTION PROGRAM

JOEL LUNDQUIST
STRESS ANALYSIS SECTION B&V ENERGY

AGENDA
About Black & Veatch Introduction Power Piping Code Initial Baseline Assessment Evaluation by Non-Destructive Examination Computerized Stress Analysis Assessment Report and Recommendations Concluding Remarks Questions
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ABOUT BLACK & VEATCH

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BLACK & VEATCH CORPORATION IS A LEADING GLOBAL ENGINEERING, CONSULTING AND CONSTRUCTION COMPANY
Founded in 1915 Global workforce of more than 9,000 More than 100 offices worldwide Projects in more than 100 countries on 6 continents $2.6 billion in annual revenues in 2011 Ranked on Forbes Americas Largest Private Companies listing One of the largest majority employee-owned companies in the U.S. Reputation of integrity, competence and highest safety standards
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BLACK & VEATCH CONSULTING PVT LTD (PUNE)

Business in India from 1977; office established in 2004 Business Areas Energy and Telecom Workforce More than 150 professionals Energy Departments Engineering (Mechanical, Electrical & Controls, Civil & Structural), Project Control, Proposals, Procurement, Quality, Human Resources, and Administrative Office with project execution capabilities Equipped with commercial and B&V proprietary engineering tools

INTRODUCTION

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INTRODUCTION
Piping failures can result in equipment damage, costly repair, unit outages and injury to plant personnel Pipe supports functioning improperly can result in sagging pipe, undue piping stresses and increased loading on equipment connections

A High Energy Piping (HEP) inspection program will assess and monitor condition of piping and supports to identify issues early

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INTRODUCTION
Black & Veatch (B&V) has assisted many utilities in developing and implementing HEP inspection programs for fossilfueled power generating facilities in North and South America Discuss B&Vs typical approach for initial assessment, development and implementation based upon ASME B31.1 Power Piping Code, industry practice and past experience

POWER PIPING CODE

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POWER PIPING CODE

Chapter VII of ASME B31.1 includes requirements for establishing program to assess and document condition of HEP or covered piping systems to ensure safe unit operation Code defines covered piping systems (CPS) Systems generally include NPS 4 and larger of main steam, hot reheat steam, cold reheat steam and boiler feedwater Other piping systems may be included due to past operating history or damaging transient events
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POWER PIPING CODE

Non-mandatory Appendix V of ASME B31.1 provides further recommendations for minimum requirements for establishing program Requirements and recommendations of ASME B31.1 are framework that B&V uses to perform condition assessments and develop HEP programs for clients

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INITIAL BASELINE ASSESSMENT

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OPERATING HISTORY
Operating hours and modes of operation Typical operating temperatures, number and frequency of significant temperature excursions Past dynamic events Discussion of inspection program or past inspections Past non-destructive examination (NDE) Planned outage schedule

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DOCUMENTATION REVIEW
Past hanger inspection data Piping and support drawings for HEP Documentation for original piping material specifications, diameter, wall thickness, design temp. and pressure Past inspection or NDE reports Steam turbine outline and stop valve drawings, allowable forces and moments Boiler drawings including thermal movements, allowable forces and moments Records for past piping or support modifications
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INSPECTION OF PIPING AND SUPPORTS

Observe and record travel position for springs in hot and cold position Pipe support locations and type match drawings Loose, missing, damaged, or broken hardware Damaged or corroded hardware

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INSPECTION OF PIPING AND SUPPORTS

Evidence of damaging dynamic or transient events Damaged or modified insulation Observe steam lines for proper slope towards drain pots Proper thread engagement Proper gaps for pipe restraints Interference of piping or supports with adjacent pipe, steel, or equipment Record pipe temperature at time of inspection Inspections recommended to be performed on annual basis as minimum
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CONSTANT SPRING SUPPORTS

Observe and record travel position in the hot and cold position Compare against original design and past inspections

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VARIABLE SPRING SUPPORTS

Observe and record travel position in the hot and cold position Compare against original design and past inspections

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RIGID HANGERS
Confirm adequate thread engagement, signs of clamp damage or bent rod

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HYDRAULIC SNUBBERS
Inspect for evidence of free thermal expansion, damage, signs of hydraulic fluid leakage and fluid level

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RIGID STRUT
Inspect for loose hardware or signs of damage

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LIMIT STOP
Ensure proper gaps in the cold and hot position

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EVALUATION BY NON-DESTRUCTIVE EXAMINATION (NDE)

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EVALUATION BY NDE
NDE recommended at key locations to identify defects and determine remaining life for piping Key locations determined by areas of concern during visual inspections, results of past NDE, experience, and industry practice Locations often categorized by priority to accommodate outage timing or duration Various types may be employed

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HIGHER PRIORITY
Turbine inlet, stop valve inlet, stop valve outlet, boiler inlet, and boiler outlet girth welds Girth welds for piping wyes Crotch of piping wyes Seam for seam welded piping Welded lugs and stanchions for highly loaded pipe supports Key pipe segments and bends for flow erosion thinning Confirmation if seam weld is present Locations visibly damaged due to dynamic or transient event

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MEDIUM PRIORITY
Welded pipe lugs and stanchions for less highly loaded pipe supports Inspection of branch connection welds

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INSPECTION FREQUENCY
Generally five years or 35,000 operating hours between first and second inspection of particular location Interval between second and the next test is determined by comparison of the first and second test Qualified NDE contractor can also provide recommendations regarding frequency of inspection

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TYPES OF NDE
Visual Examination For visible surface defects Positive Material Identification Confirm piping material Pi Tape Diameter Measurement Measure outside diameter Wet Fluorescent Magnetic Particle Identify surface defects in weld and base metal Ultrasonic Wall Thickness Measurement Measure wall thickness for use in stress analysis and identify wall thinning
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TYPES OF NDE
Linear Phased Array
Ultrasonic inspection method for defect detection in pipe welds

Time of Flight Diffraction

Another ultrasonic method for defect detection in pipe welds

Replication
Inspect microstructure for creep damage

Acid Etch
Surface examination for presence of seam weld

Acoustic Emissions Monitoring

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NDE CONTRACTOR
NDE shall be performed by qualified contractor NDE shall be performed in accordance with written procedures prepared by the contractor and approved by certified inspector Microstructures from replications shall be interpreted by metallurgist experienced in evaluating microstructures for creep damage Contractor shall document results in detailed report that provides summary of testing completed, results, photographs, locations tested, recommendations for future inspections, and exact location of rejectable indications

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COMPUTERIZED STRESS ANALYSIS

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COMPUTERIZED STRESS ANALYSIS

Piping and hanger inspections may reveal issues which require evaluation by stress analysis

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COMPUTERIZED STRESS ANALYSIS

As-Designed Analysis Based on original design parameters to compare against original analysis. Baseline for other analyses As-Built Analysis Include any discrepancies between original design documents and inspections As-Existing Analysis As observed during hot inspections As-Modified Analysis Include recommended support additions, replacement, or modification
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ASSESSMENT REPORT AND RECOMMENDATIONS

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REPORT AND RECOMMENDATIONS

Following personnel discussions, documentation review, and support inspections, B&V prepares a report which summarizes evaluation and provides recommendations Summarizes and identifies areas of concern regarding past operating history and documentation review Results and findings of piping and support inspections, including tables documenting spring hanger position and support observations Recommendations for NDE, including, inspection locations marked on drawings and spreadsheet indicating inspection methods at each location

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REPORT AND RECOMMENDATIONS

Recommendations for hanger adjustments, repairs or replacement Load testing of certain springs may be recommended Recommendations for follow-up inspections following hanger repair or replacement Computerized stress analysis may be recommended to determine root cause and corrective actions for piping or support performance issues observed

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CONCLUDING REMARKS

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CONCLUDING REMARKS
Development and implementation of plan to assess and monitor condition of HEP and supports is crucial Initial baseline assessment Plan for future inspections Will aid in identifying issues early to avoid costly repairs, equipment damage, unscheduled outages, injury to plant personnel

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