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STRESS ANALYSIS SECTIONB&V ENERGYJOEL LUNDQUIST
HIGH ENERGY PIPING INSPECTION PROGRAM
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Ap
ril
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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
Questions2
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 “America’s 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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• 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&V’s 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
COMPUTERIZED 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
COMPUTERIZED STRESS ANALYSIS
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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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