Optimizing reformer tube life through advanced inspection and remaining life assessment

2010 ◽  
Vol 29 (4) ◽  
pp. 299-304 ◽  
Author(s):  
B.E. Shannon ◽  
C.E. Jaske ◽  
M.C. Smith
Keyword(s):  
Life Assessment ◽  
Remaining Life ◽  
Remaining Life Assessment ◽  
Tube Life ◽  
Reformer Tube

Latest Developments in Optimizing Reformer Tube Life Through Advanced Inspection and Remaining Life Assessment

2013 ◽  
Author(s):  
Brian Shannon ◽  
Carl E. Jaske
Keyword(s):  
Operating Conditions ◽  
Life Assessment ◽  
Inspection System ◽  
Remaining Life ◽  
Centrifugally Cast ◽  
Steam Methane ◽  
Recent Developments ◽  
Reformer Tubes ◽  
Remaining Life Assessment ◽  
Tube Life

Steam methane reformer tubes must withstand high temperature and pressures during operation and are made from centrifugally cast austenitic materials, typically HK-40, HP Modified, and Micro-Alloy materials. Since operating conditions can result in various forms of damage, the identification and quantification of damage is of vital importance if tube life is to be predicted accurately. This paper describes the recent developments in an integrated inspection system which uses multiple NDT techniques to provide a most comprehensive assessment of current tube condition. This system is coupled with a sophisticated remaining life assessment software model which predicts the remaining life of each tube in a furnace.

Structural Response and Remaining Life of Damaged Composites

2015 ◽  
Vol 813-814 ◽  
pp. 106-110
Author(s):  
Dalbir Singh ◽  
C. Ganesan ◽  
A. Rajaraman
Keyword(s):  
Hybrid Approach ◽  
Experimental Studies ◽  
Structural Response ◽  
Material Behavior ◽  
Experimental Results ◽  
Life Assessment ◽  
Nonlinear Material ◽  
Remaining Life ◽  
Design Effectiveness ◽  
Remaining Life Assessment

Composites are being used in variety of applications ranging from defense and aircraft structures, where usage is profuse, to vehicle structures and even for repair and rehabilitation. Most of these composites are made of different laminates glued together with matrix for binding and now-a-days fibers of different types are embedded in a composite matrix. The characterizations of material properties of composites are mostly experimental with analytical modeling used to simulate the system behavior. But many times, the composites develop damage or distress in the form of cracking while they are in service and this adds a different dimension as one has to evaluate the response with the damage so that its performance during its remaining life is satisfactory. This is the objective of the present study where a hybrid approach using experimental results on damaged specimens and then analytical finite element are used to evaluate response. This will considerably help in remaining life assessment-RLA- for composites with damage so that design effectiveness with damage could be assessed. This investigation has been carried out on a typical composite with carbon fiber reinforcements, manufactured by IPCL Baroda (India) with trade name INDCARF-30. Experimental studies were conducted on undamaged and damaged specimens to simulate normal continuous loading and discontinuous loading-and-unloading states in actual systems. Based on the experimental results, material characterization inputs are taken and analytical studies were carried out using ANSYS to assess the response under linear and nonlinear material behavior to find the stiffness decay. Using stiffness decay RLA was computed and curves are given to bring the influence of type of damage and load at which damage had occurred.

scholarly journals The thermal history and stress state of a fresh steam-pipeline influencing its remaining service life

2011 ◽  
Vol 15 (3) ◽  
pp. 691-704 ◽  
Author(s):  
Gordana Bakic ◽  
Vera Sijacki-Zeravcic ◽  
Milos Djukic ◽  
Stevan Maksimovic ◽  
Dusan Plesinac ◽  
...  
Keyword(s):  
Service Life ◽  
Elevated Temperatures ◽  
Operating Temperature ◽  
Life Assessment ◽  
Temperature History ◽  
Significant Variable ◽  
Remaining Life ◽  
Pipe Bend ◽  
Steam Pipeline ◽  
Remaining Life Assessment

The service life of thick-walled power plant components exposed to creep, as is the case with pipelines of fresh- and re-heated steam, depend on the exhaustion rate of the material. Plant operation at elevated temperatures and at temperatures below designed temperatures all relates to the material exhaustion rate, thus complicating remaining life assessment, whereas the operating temperature variation is a most common cause in the mismatching of real service- and design life. Apart from temperature, the tube wall stress is a significant variable for remaining life assessment, whose calculation depends on the selected procedure, due to the complex pipeline configuration. In this paper, a remaining life assessment is performed according to the Larson-Miller parametric relation for a ?324?36 pipe bend element of a fresh steam-pipeline, made of steel class 1Cr0.3Mo0.25V, after 160 000 hours of operation. The temperature history of the pipeline, altogether with the pipe bend, is determined based on continuous temperature monitoring records. Compared results of remaining life assessment are displayed for monitored temperature records and for designed operating temperature in the same time period. The stress calculation in the pipe bend wall is performed by three methods that are usually applied so to emphasize the differences in the obtained results of remaining life assessment.

Comparative Study on Remaining Life Assessment of a Pressure Vessel, Working in Severe Conditions, Based on Results of Metallographic Replicas and Creep Tests

2021 ◽  
Vol 1164 ◽  
pp. 67-75
Author(s):  
Iuliana Duma ◽  
Alin Constantin Murariu ◽  
Aurel Valentin Bîrdeanu ◽  
Radu Nicolae Popescu
Keyword(s):  
Stainless Steel ◽  
Life Assessment ◽  
Petrochemical Plant ◽  
Remaining Life ◽  
Creep Tests ◽  
Experimental Creep ◽  
Asme Code ◽  
Remaining Life Assessment ◽  
Service Duration ◽  
Made In

The paper presents and compares the results on the reliability and remaining life assessment of a reactor (coxing box) from a petrochemical plant. The reactor shell is made of 16Mo5 (W1.5423) steel, with a thickness of 25 mm, plated with 3 mm thick X6CrAl13 (W1.4002) stainless steel. The assessment was made in two steps. For preliminary remnant life assessment, specifications of section VII of the ASME code was used followed by iRiS‑Thermo expert system. Further, experimental creep and metallographic replica analysis were performed. Results comparison of the two methods applied revealed a reduction of the preliminary estimated remaining live obtained using metallographic replica analysis. Based on the results obtained, the possibility to extend the service duration of the coxing box in the safety condition, using current process parameters, with of 20.000 hours was highlighted.

Elevated-Temperature Life Assessment

2021 ◽  
pp. 146-166
Author(s):  
Arun Sreeranganathan ◽  
Douglas L. Marriott
Keyword(s):  
High Temperature ◽  
Elevated Temperature ◽  
Stress Relaxation ◽  
Damage Mechanics ◽  
Elevated Temperatures ◽  
Constitutive Models ◽  
Life Assessment ◽  
Remaining Life ◽  
High Temperature Components ◽  
Remaining Life Assessment

Abstract This article provides some new developments in elevated-temperature and life assessments. It is aimed at providing an overview of the damage mechanisms of concern, with a focus on creep, and the methodologies for design and in-service assessment of components operating at elevated temperatures. The article describes the stages of the creep curve, discusses processes involved in the extrapolation of creep data, and summarizes notable creep constitutive models and continuum damage mechanics models. It demonstrates the effects of stress relaxation and redistribution on the remaining life and discusses the Monkman-Grant relationship and multiaxiality. The article further provides information on high-temperature metallurgical changes and high-temperature hydrogen attack and the steps involved in the remaining-life prediction of high-temperature components. It presents case studies on heater tube creep testing and remaining-life assessment, and pressure vessel time-dependent stress analysis showing the effect of stress relaxation at hot spots.

An Authoritative Comparison of Remaining Life Assessments for Pipeline Dents

2018 ◽  
Author(s):  
Rhett Dotson ◽  
Chris Holliday ◽  
Luis Torres ◽  
Damien Hagan
Keyword(s):  
Finite Element ◽  
American Petroleum Institute ◽  
Assessment Methods ◽  
Ease Of Use ◽  
Life Assessment ◽  
Finite Element Models ◽  
Remaining Life ◽  
Calculated Stress ◽  
Stress Concentration Factors ◽  
Remaining Life Assessment

A significant amount of effort has been expended in the area of advancing pipeline dent remaining life assessment methods beginning in the late 1980s and extending to the current day. Initial research efforts were primarily empirical in nature while more recent research efforts have incorporated finite element modelling. Coupled with advancements in assessment techniques, the capabilities of advanced in-line inspection (ILI) tools have increased to a point where they can provide consistent, reliable information that is suitable for dent assessments. As a result of these advancements in assessment models and ILI tools, operators can now perform remaining life assessments using ILI data, and a multitude of remaining life assessment models are available, including solutions from the European Pipeline Research Group (EPRG), Pipeline Research Council International (PRCI), American Petroleum Institute (API), and finite-element based approaches. In addition to these remaining life assessments, many operators routinely perform strain-based assessments based on guidance from ASME B31.8. To date, there have been few studies comparing the various assessment methods on large numbers of dents, and as a result, significant questions persist as to the conservatism inherent in each method. In addition, the EPRG and PRCI methods are largely based on full-scale testing and finite-element models performed with idealized indenter shapes while actual pipeline dents typically exhibit complex shapes and interactions between multiple dents. Each model also has limitations and advantages that are discussed in this paper, such as ease of use and how pipeline geometry and weld association are considered. This paper provides a robust comparison of selected dent assessment methodologies on 220 actual dents from a 24-inch pipeline with depths ranging from 0.6–4.5% OD, and 32 dents from a 30-inch line with depths ranging from 1–2.5% OD. The assessment includes both top and bottom of line dents and investigates the influence of restraint on remaining life. The results presented in the paper are based on high-resolution ILI caliper data collected during two in-line inspections. Furthermore, the paper provides statistical comparisons between strain and remaining life methodologies and also between the various remaining life assessments. The paper also provides a comparison of the restraint parameter from the PRCI model with calculated stress concentration factors from finite-element models. The paper provides a first of its kind comparison of the various methods and discusses how the work may be extended to other pipe diameters and wall thicknesses.

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