ASME B31.1 Operation and

Maintenance Requirements-From

a Code Perspective

2014 IDEA Campus Workshop

Monte K. Engelkemier, P.E.

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

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

History of B31.1 O&M

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.

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

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.

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

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.

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)

“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

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.

OPERATION AND MAINTENANCE

PROCEDURES

• The Operating Company shall be responsible for the safe operation and maintenance of their power piping.

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.

Condition Assessment

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

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.

O&M Procedures

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

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

Records

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.

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

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

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

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

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

Desuperheater Supply Piping Failure Failure occurred between gate valve & elbow **THIS IS NOT A CONTROL VALVE, IT IS OPEN OR CLOSED**

Before After

A Common Pressure Failure Example: Banana Effect

• What happens when a Desuperheater is

used too much?

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

Grout busted loose from the water

hammer

Notice Crack in soil around pier. The

crack was observed to be about 1 ½ to 2

inches wide

Thermal Gradient

During Operation

LHot (Toperating)

LCold (Toperating)

During Shutdown

LCold = LHot at Toperating

LCold ≠ LHot at 70 F

The Big Effect

• Piping not uniformly heated causing:

– Supports to lift off

– Permanent Deformation of the Piping

– Almost killing workers

Spring Topped Off

Support lifts up so let’s shim it! Not once, not twice, but three or four times.

Let’s shim here too.

Flow Element popped up ~24”, shearing the last bolts. Eventually coming to rest 8” above intended elevation.

Notice the sledge hammer.

There was one worker on either side of the pipe, if pipe goes left or right they’re dead.

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

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.

Thank-you! Questions???

Contact Information:

Monte K. Engelkemier, P.E.

engelkemierm@stanleygroup.com

563-264-6641 work