High Energy Piping Inspection

STRESS ANALYSIS SECTIONB&V ENERGYJOEL LUNDQUIST

HIGH ENERGY PIPING INSPECTION PROGRAM

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AGENDAAbout Black & Veatch

Introduction

Power Piping Code

Initial Baseline Assessment

Evaluation by Non-Destructive Examination

Computerized Stress Analysis

Assessment Report and Recommendations

Concluding Remarks

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ABOUT BLACK & VEATCH

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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

BLACK & VEATCH CORPORATION IS A LEADING GLOBAL ENGINEERING, CONSULTING AND CONSTRUCTION COMPANY

POWER-GEN India 21 April 2012

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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

BLACK & VEATCH CONSULTING PVT LTD (PUNE)

POWER-GEN India 21 April 2012

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INTRODUCTION

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

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

INTRODUCTION

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21 April 2012POWER-GEN India

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Black & Veatch (B&V) has assisted many utilities in developing and implementing HEP inspection programs for fossil-fueled 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

INTRODUCTION

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POWER PIPING CODE

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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

POWER PIPING CODE

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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

POWER PIPING CODE

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INITIAL BASELINE ASSESSMENT

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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

OPERATING HISTORY

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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

DOCUMENTATION REVIEW

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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

INSPECTION OF PIPING AND SUPPORTS

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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

INSPECTION OF PIPING AND SUPPORTS

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Observe and record travel position in the hot and cold position

Compare against original design and past inspections

CONSTANT SPRING SUPPORTS

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Observe and record travel position in the hot and cold position

Compare against original design and past inspections

VARIABLE SPRING SUPPORTS

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

RIGID HANGERS

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

HYDRAULIC SNUBBERS

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Inspect for loose hardware or signs of damage

RIGID STRUT

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Ensure proper gaps in the cold and hot position

LIMIT STOP

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EVALUATION BY NON-DESTRUCTIVE EXAMINATION (NDE)

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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

EVALUATION BY NDE

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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

HIGHER PRIORITY

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Welded pipe lugs and stanchions for less highly loaded pipe supports

Inspection of branch connection welds

MEDIUM PRIORITY

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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

INSPECTION FREQUENCY

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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

TYPES OF NDE

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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

TYPES OF NDE

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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

NDE CONTRACTOR

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COMPUTERIZED STRESS ANALYSIS

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


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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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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

REPORT AND RECOMMENDATIONS

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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

REPORT AND RECOMMENDATIONS

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CONCLUDING REMARKS

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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

CONCLUDING REMARKS

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QUESTIONS?

PLEASE VISIT US AT:

BOOTH # 1139, HALL 11

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www.bv.com

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High Energy Piping Inspection

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