high energy piping inspection - .: national power … prstn_thermal april2012… · high energy...

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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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&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


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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

high energy piping inspection - .: national power … prstn_thermal april2012… · high energy...

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