aim condition assessment (2)
Post on 18-Jan-2017
281 Views
Preview:
TRANSCRIPT
Tata ProjectsQuality Services-AIM
Date: 03-02-2016
1. Scope of coverage2. Definition of deliverables3. Roles and responsibilities 4. Methodology- Condition assessment & Remaining
life assessment.5. Case studies6. Plan of action- proof of concept, phases, scaling
methodology and repeat of RLA cycle (long term engagement).
TABLE OF CONTENTS
Scope: Condition Assessment & RLA 1. Industrial risk: a. Identify: Damage mechanism b. Assessment- Condition Assessment & RLA c. Periodic Inspection at regular intervals
Definition of Deliverables
Recommendations :
- Maintain in operation as is / Re-rate
- For Repair
- Replace
- Inspection plan
5
Methodology
Inputs from Plant / Client
Review of Design Data & Inputsa)If authentic design data is availableb)If Not,Reverse Engineering will be done to establish the design data with pre-bid inspection survey.
Team Of Experts for Pre BID Inspection Survey Involves –1. Design Engg. 2. Inspection Expert 3. Static Eqpt. Expert 4. NDT Expert 5. Corrosion Expert
6
Methodology
Inspection Data Analysis , evaluation & calculations
use as is, Repair, alteration and rerating
Planning of Site Visit – Inspection, Examination and Testing
Recommendations on RLA & Condition Assessment
7
1. General and local Metal loss2. Surface connected cracking3. Subsurface cracking4. Micro fissuring/micro void formation5. Metallurgical changes6. Blistering7. Dimensional Changes8. Material properties changes
Modes of deterioration and Failure
8
1. Internal Inspection2. On-stream inspection3. External Inspection4. Thickness inspection5. Corrosion under insulation
Types of inspection & Surveillance
9
1.Fluorescent or dye penetrant examination2.Magnetic Particle Examination3.Radiographic Examination4.Ultrasonic thickness measurement5.Alternating current flux leakage examination6.Eddy current examination7.Field metallographic replication8.Thermography9.Pressure testing10.Advanced NDT (PAUT, LRUT & TOFD)11.Free run Tests
Examination technique
10
1. Corrosion rate determination2. Remaining life calculation3. Maximum allowable working pressure
determination4. Condition assessment5. Rerating of equipment.
Inspection Data Analysis & Evaluation
11
Case Study Remaining Life Assessment
of Pressure vessels
12
Nitrogen Pressure Vessels
Received an Order from Ambuja Cement for the Residual Life Assessment of Pressure vessels
13
Nitrogen Pressure Vessels
Name of Manufacturer M/S MVS Engineering Ltd
Position Vertical
Dimensions Dia 2.3 MTS x 10.7 MTRS Length ,Shell 25mm thick and Dish 25 mm thick
Material Carbon Steel
Drawing No. CL-223
Date on which first taken in use 2005
Safe Working Pressure Recommended by manufacturer
25 kg/cm2
Date of last Examination 17/10/2011
Date of last NDT Examination 17/10/2011
Date of last Hydro Test Record 04/04/2011
Safe Working Pressure 25 Kg/sqcm
14
Case Study Condition Assessment of
KVK Nilachal Thermal power plant
Capacity: 1 x 350 MW
15
Condition Assessment: Structural Stability S. No. Area of Assessment
1 Boiler Pressure parts: Boiler Drum,Super heater tubesReheater tubesEconomiser tubesHeadersWater wall panels
2 Boiler Structure
3 Boilers Structural Parts
4 Equipment : Bowl millHopper
5 ESP Structures erected
16
Condition Assessment: Structural Stability Sl.
No.Civil: Area of Assessment
1 Turbine Generator Building
2 Chimney
3 Mill Foundation
4 Boiler Feed Pump foundation
5 ESP control Room
6 PA & FD Fan duct support foundation
7 ID fan foundation
8 Electrical Control Room
9 Power house building
17
Condition Assessment: Structural Stability
18
Materials Analysis and Examination
197/19/2006
ULTRASONIC EXAMINATION SCANNING DETAIL SHEET
SCANNING DETAIL
MH-3 (24” Manhole) ID: 610mmThk: 105mmPad Plate: 60mm
View from Inside
MH10Length: 22 mm (*) (**) (Trans)Depth: 2mm (case 8)
MH11Length: 20mmDepth: 17mm (case 7 or 8)
MH12Length: 22 mm (*) (**) (Trans)Depth: 2mm (case 7)
MH01Length: 70mmDepth: 38mm (Case 7) MH02
Length: 22 mm (*) (Trans)Depth: 2mm (case 7)
MH03Length: 22 mm(*)(Trans)Depth: 3mm (case 7)
MH04Length: 30mmDepth: 3mm
MH05Length: 50mmDepth: 10mm (case 8)
MH06 Two indications 40 mm & 170 mm (Does not appear to be cracks, weld groove side wall-TWI)MH08
Length: 180mmDepth: 27mm (Case 9a)
MH09 Length: 22 mm (*) (Trans)Depth: 4mm
Weld
WeldMH7aLength 55 mm (established by visual and PT)
MH07bLength: 20 mmDepth: Through wall established by UT (Case 9b)
MH07 Crack is visible from outside at weld going towards 60 mm tapered area (Case 9b).
75 mm
Note: The depth of crack in 55 mm length in weld and tapered section could not be established. The reason is anticipated skewing of the beam or possibly attenuate the ultrasound altogether.
Length: 31 mm as seen in photo
(*) Length from weld width
(**) MH10 & 12 as too close from MH11
30mm
20mm
Rev 01
Condition Assessment & RLA –Benefits
Plan of Action
22
References for GuidelineASME Section V – NDTASME Section VIII Division I latest edition - Design & NDT Acceptance ASME FFS 1- Fitness for serviceAPI 510-Press.Vessel Inspection code (Insp,rating,repair & alteration)API 570-Piping Insp.( Inspection, rating, repair & alteration of in process piping)API 579 –Fitness for serviceAPI 580-Risk Based InspectionAPI 581 –Risk based inspection TechnologyAPI 653 -Tank Inspection, Repair, Alteration, and Reconstruction
23
THANK Q
top related