make sure lock out 2 - ndt.net
TRANSCRIPT
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MAKE SURE LOCK OUT
BEFORE START THE WORK
Badak LNG Overview
Problem Description and Assessment Approach
Examination Result
Assessment Result
Conclusions
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2
3
4
5
3
4
C
F
G
Gas Pipelines
Oil Pipelines
10%
15%
20%
55%Shareholders
INDONESIA
1, 2, 3…: LNG storage tank
AB
C
D
E
F
G
H
G/H
C/D
A/B
Cold Water Intake
Dock 2
Dock 1
Dock 3LPG
Plant
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34
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1, 2, 3…: LNG storage tank
Cooling Water Intake
DOCK 2
DOCK 1
DOCK 3
LPGPlant
A
BC
D
E
F
G
H
LNG train
LNG storage tank
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No. Trains : 8 (22.5 MTPA LNG & 1.1 MTPA LPG)Loading Docks : 3 (1 LNG, 2 LNG/LPG)
Feed Gas Supply : 3.7 BSCFD with 4 Pipelines 2@36”; 2@42”
Boiler Boiler
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LetdownStation
Steam Condensate Utilities -1
NC
LetdownStation
LetdownStation
LetdownStation
Back Press.Turbine
CompressorDriver
CompressorDriver
Back Press.Turbine
Steam Condensate Utilities -2
CondensingTurbine
CondensingTurbine
PumpDriver
PumpDriver
HP Steam 61-62 kg/cm 2g ;
450 oC
MP Steam17.5 kg/cm 2g ;
316 oC
LP Steam3.5 kg/cm 2g ;
218 oC
Boiler Utilities-1 Boiler Utilities-2
Surface
Condensers
Surface
Condensers
Note: Green : Open, Red : Close
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Design code ANSI B 16.34
Size / ANSI Class 24” / 600
Valve type Gate flexible wedge type disc
Year installed 1989
Material specification
ASTM A217 WC6
ServiceHigh pressure superheated steam
Design pressure 75 kg/cm2g (1066 Psig)
Design temperature
450 ºC (842 ºF)
Operating pressure 61- 62 kg/cm2g (882 psig)
Operating temperature
450 ºC (842 ºF)
Insulation N/A
N
Utilities -2 Utilities-1
Cracked Valve
Crack occurred at two locations: Body
and Bonnet
� Material Test
� Flaws Sizing : Alternating Current Potential Drop (ACPD)
� Thickness Measurement : Ultrasonic Test
� Material Characterization:
Chemical Composition, Tensile Testing, Fracture Toughness (CTOD) Testing and Fatigue Growth Testing
� Finite Element Modelling : Abacus
Software
� Fitness for Service Assessment: APII
579 Section 9 Level 3B
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Red : Crack B, blue: Crack C, green: Crack D and
yellow Crack E
Crack A on valve Body
9Flaw Length A = 170 mm, B = 33 mm, C = 120 MM, D = 70 mm, & E = 23 mm)
10Note:Thickness of Remaining Ligament = Average Thickness – Maximum Crack Height
Material Characterization
Test Type Result and Remark
Chemical CompositionMeet Requirement ASTM A 217 Grade WC6 but siliconcontent exceeded 0.6%
Tensile Testing
� Test at 23 ºC Meet Requirement ASTM A 217 Grade WC6
� Test at 130 ºC YS = 225 MPa, TS = 487 MPa, EL = 16 %, RA = 23 %
Fracture Toughness (CTOD) at 130 ºC
Minimum value is 0.38 mm
Fatigue Growth Testing at 130 ºC
A = 3.1x10-17, m = 4.4 and ∆Ko = 184 Nmm-3/2
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Bonnet Cap
Bonnet
West Side
East Side
End Cap
West SideEast Side
Case LocationAverage Von-Mises
stress (MPa)Stress range, ∆σ (MPa)
Low temperatureValve body 103.5 -
Bonnet 89.5 -
High temperatureValve body 175.5 -
Bonnet 163.5 -
Low temperature minus 10 ºCValve body 102.5 -
Bonnet 85 -
Low temperature plus 20 ºCValve body 107 -
Bonnet 94 -
Low temperature – 10 ºC + 20 ºCValve body - 4.5
Bonnet - 9
Low - High temperatureValve body - 72
Bonnet - 74
Valve Temperature Low Temperature Case High Temperature Case
West Side 114.4 ºC 415 ºC
Bonnet 73 ºC 402 ºC
East Side 70.6 ºC 412 ºC
Note:
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Failure Assessment Diagram
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Str
es
s In
ten
sit
y R
ati
o,
Kr
Load Ratio, Lr
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Fla
w H
eig
ht,
a (
mm
)
Flaw Length , 2c (mm)
Unsafe
Safe
Crack Critical Value for Bonnet
16
Fla
w H
eig
ht,
a (
mm
)
Flaw Length , 2c (mm)
Unsafe
Safe
Case Remark
Crack on Body
� Low Temperature Case –10 ºC + 20 ºC No crack growth
� Swing between low and high Temperature Case
Crack growth occurred
Crack on Bonnet
� Low Temperature Case –10 ºC + 20 ºC No crack growth
� Swing between low and high Temperature Case
Crack growth occurred
Crack Growth Analysis
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Crack Growth Analysis - Body
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Crack Growth Analysis - Bonnet
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� The 170 mm long flaw located at the valve body had a semi-elliptical shape with a maximum height of 31.8 mm.
� The equivalent flaw size on bonnet was determined to be 16 mmhigh and 130 mm long.
� Valve body flaws are in the safe region of the API 579 Level 3Bfailure assessment diagram.
� Crack growth analysis showed that the crack on valve not likely togrow if the valve experiences limited temperature cycling (between10 ºC below to 20 ºC above the low temperature case) but sub-critical growth of the body crack will occur if the valve experiencestemperature cycling between the low and the high temperaturecase
� Close monitoring of temperature has been conducted to preventany temperature swing beyond lower temperature case.
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