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This document summarizes a presentation about ASME B31.1 requirements for operation and maintenance (O&M) of piping systems from a code perspective. It discusses the history and organization of O&M requirements in the B31.1 code, including the addition of Chapter VII in 2007. It outlines the goals of O&M, including managing piping safety throughout its lifespan and conducting condition assessments. Examples of common pressure pipe failures that prompted improved O&M are also summarized, such as a desuperheater piping failure caused by thermal stresses known as the "banana effect".
Pipininspect
- 1. ASME B31.1 Operation and Maintenance Requirements-From a Code Perspective 2014 IDEA Campus Workshop Monte K. Engelkemier, P.E.
- 2. Agenda • Organization of ASME B31.1 • History of O&M • Goals of O&M • Condition Assessment • O&M Procedures • Records • A Common Pressure Failure Example: Banana Effect
- 3. Organization of ASME B31.1 Committee • Main Committee* • Subgroups (Chapters & Appendices) – General Requirements (CH I & IV, APP F-J) – Design* (CH II, MA D, NMA II) – Materials (CH III, MA A-C, NMA V) – Fabrication & Examination (CH V & IV, – Operation & Maintenance* (CH VII, NMA V) – Special Assignments (Everything Else) *Member • Personally involved with ASME B31.1 Since 2006; currently the Design and O&M Secretary; Member of the New FRP Code
- 4. History of B31.1 O&M
- 5. Acknowledgement Joe Frey, P.E., one of the driving forces behind the scenes to get the initial version of Chapter VII into the 2007 Edition of Code. Current Chairman of B31.1.
- 6. Two Papers on the Subject • EPRI 1018998 Guideline for Compliance to B31.1 Chapter VII, Operation and Maintenance • ASME PVP-26069 High-Energy Piping Systems are Now Covered Piping Systems
- 7. Chapter VII Operation & Maintenance • ASME B31.1 addresses the operation and maintenance of power piping 2007 edition. • The inspection and evaluations methods are acknowledged, but not detailed. • Wanted Owners to have a plan to address O&M. It didn’t need to be a great plan, but something was better than nothing.
- 8. APPENDIX V • Predates Chapter VII • Added to B31.1 after Mohave Failure 6/9/85 • Nonmandatory • How to “maintain” critical piping • Where details of condition assessment are introduced into the Code • Overtime portions of Appendix V are being merged into Chapter VII
- 9. The W. A. Parish 8 CR Seam Weld Failure Prompted Two Industry Reactions: 1. Seal welded cold reheat systems were added to the inspection programs – fatigue cracks 2. ASME B31.1 Code Committee renewed efforts on Appendix V and then began work on a new mandatory operation and maintenance chapter. Chapter VII was published in December of 2007.
- 10. Other ASME Codes with O&M Requirements • B31.4 – 2002 Pipeline Transportation Systems For Liquid Hydrocarbons and Other Liquids (Chapter VII) • B31.8 – 2003 Gas Transmission And Distribution Systems (Chapter V) • B31.11 – 2002 Slurry Transportation Piping Systems (Chapter VII) • High Pressure System HPS 2003 (Section 5000)
- 11. “Thou Shall Know the Condition of Thy Condition” -Piping Gods (Before We Knew it was Round with a Hole) Goals of B31.1 O&M
- 12. GENERAL • Managing safe pipe service begins with the initial project concept and continues throughout the service life of the system. • Any new failure reinforces this protocol.
- 13. OPERATION AND MAINTENANCE PROCEDURES • The Operating Company shall be responsible for the safe operation and maintenance of their power piping.
- 14. Covered piping systems (CPS): Piping systems on which condition assessments are to be conducted: • NPS 4 and larger MS, HRH, CRH, & BFW • NPS 4 and larger in other systems that operate above 750F or above 1025 psi. • The Operating Company may, in its judgment, include other piping systems determined to be hazardous by an engineering evaluation of probability and consequences of failure.
- 16. CONDITION ASSESSMENT OF CPS • A condition assessment shall be performed periodically based on condition. • What is a good period? – 3 Years – 5 Years – 10 Years
- 17. Basis for determining extent of assessment and re-inspection interval Consideration of the age of the CPS, the previous documented condition, anticipated operating conditions. This includes remaining life assessment.
- 18. O&M Procedures
- 19. OPERATION AND MAINTENANCE PROCEDURES (Who is Doing This?) • Operation of piping system within design limits • Documentation of system operating hours and hot, warm, and cold starts • Documentation of actual operating temperatures and pressures • Documentation of system excursions including pipe hammers • Documentation of modifications and repairs to CPS • Document hydro pinning requirements
- 20. OPERATION AND MAINTENANCE PROCEDURES • Maintenance of pipe supports • Maintenance of piping system vents, drains, and relief valves • Maintenance of steam attemperators • Assessment of deteriorating mechanisms including; creep, fatigue, corrosion, erosion • Documentation of condition of CPS • Maintenance of CPS
- 21. Records
- 22. RECORDS • The condition assessment reports and any reference documents, such as procedures required by para. 139, drawings and reports, shall be maintained and accessible for the life of the plant.
- 23. RECORDS • System name • Material specification • Design temperature and pressure • Operating temperature and pressure • Design diameter and wall thickness • Operating hours, both total and since last annual report • Hot, warm, and cold starts, both total and since last annual report
- 24. RECORDS • Pipe support hot and cold walk down readings and conditions, both past and current • List of CPS dynamic events including hammers and slugs. • Hydro test pinning requirements • Modifications and repairs • Summary of pipe system inspection findings, including list of areas of concern • Recommendations for re-inspection interval and scope
- 25. RECORDS (recommended) • Actual pipe wall thickness and OD • Fabrication and erection welding information such as material, process, and PWHT used. • Fabrication Repair history • Final Weld Adjustments Actual Measurements i.e. Cold Pull
- 26. Utility Plant/Unit Date Structure Time in Type of Failure Service Gulf States Sabine 1979 HRH bend 120,000 hrs Catastrophic (creep) Utilities Unit 1 So. Cal. Mohave 1985 HRH horiz. spool 88,000 hrs Catastrophic (creep) Edison Unit 2 Detroit Edison Monroe 1986 HRH horiz. spool 97,000 hrs Catastrophic (creep) Unit 1 Virginia Pwr Surry Unit 2 1986 BF Elbow 13 years Catastrophic (FAC) Gulf States Utilities Sabine 1992 HRH bend 212,000 hrs Through-wall leak (creep) Unit 2 Alabama Pwr (Southern Co) Gaston 1992 SH Link 156,000 hrs Through-wall leak (creep) Unit 5 Tampa Electric Gannon 1993 CRH horz Bend 150,000 hrs Catastrophic (fatigue) Unit 6 Failures Driving O&M
- 27. Utility Plant/Unit Date Structure Time in Type of Failure Service Wisconsin Electric Pleasant Prairie Unit 1 1995 BF tee branch 15 years Catastrophic (FAC) East Kentucky Power Spurlock Unit 2 1996 SH Link ~125,000 hrs Through-wall leak (creep) Virginia Power Mt. Storm Unit 1 1996 SH Link ~200,000 hrs Catastrophic (creep) Kansas City Hawthorne Unit 5 1998 SH Link ~225,000 hrs Catastrophic (creep)P & L Texas Genco W A Parish 2003 CRH horiz spool 145,000 hrs Catastrophic (fatigue)Unit 8 Kansai Elec Pwr Co Mihama 2004 FW before 185000 hrs Catastrophic Unit 3 D/a (FAC) Kansas City Iatan 2007 Desuperheater piping 27 years Catastrophic (FAC)P & L
- 28. Desuperheater Supply Piping Failure Failure occurred between gate valve & elbow **THIS IS NOT A CONTROL VALVE, IT IS OPEN OR CLOSED** Before After
- 29. A Common Pressure Failure Example: Banana Effect • What happens when a Desuperheater is used too much?
- 30. Piping Layout Anchor Anchor Steam Source and DSH to 150 PSIG Saturated Paper Mill Flow Element Short Distance before first elbow Internals ended up in a Paper Mill Strainer Basket
- 31. Grout busted loose from the water hammer
- 32. Notice Crack in soil around pier. The crack was observed to be about 1 ½ to 2 inches wide
- 33. Thermal Gradient During Operation LHot (Toperating) LCold (Toperating) During Shutdown LCold = LHot at Toperating LCold ≠ LHot at 70 F
- 34. The Big Effect • Piping not uniformly heated causing: – Supports to lift off – Permanent Deformation of the Piping – Almost killing workers
- 36. Support lifts up so let’s shim it! Not once, not twice, but three or four times.
- 37. Let’s shim here too.
- 38. Flow Element popped up ~24”, shearing the last bolts. Eventually coming to rest 8” above intended elevation. Notice the sledge hammer.
- 39. There was one worker on either side of the pipe, if pipe goes left or right they’re dead.
- 40. Recommendations • Better control of DSH • Return supports to their original design • Bolt-up new Flanged Element in a stress free state, cut and miter existing 45 run to accomplish this • Perform NDE to determine if the whole system should be replaced in a future shutdown • Reevaluate System Drains
- 41. How it was Fixed • Spring Cans were returned to their original setting, shims were used to take-up the gap. • The 45 degree section shown, was cut and mitered to take up the offset caused. (ONE TIME FIX) • Next time, replace the system.
- 42. Thank-you! Questions??? Contact Information: Monte K. Engelkemier, P.E. engelkemierm@stanleygroup.com 563-264-6641 work