Optimising reformer tube life by applying advanced inspection and remaining life assessment technology

2009 ◽  
Vol 51 (4) ◽  
pp. 207-211 ◽  
Author(s):  
B E Shannon ◽  
C E Jaske
Keyword(s):  
Life Assessment ◽  
Remaining Life ◽  
Assessment Technology ◽  
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.

Remaining Life Assessment Technology Applied to Steam Turbines and Hot Gas Expanders

2011 ◽  
Author(s):  
Phillip Dowson ◽  
David Dowson
Keyword(s):  
Fatigue Life ◽  
Oil Refinery ◽  
Life Assessment ◽  
Life Extension ◽  
Remaining Life ◽  
Steam Turbines ◽  
Hot Gas ◽  
Creep Fatigue ◽  
Assessment Technology ◽  
Remaining Life Assessment

In today’s market place, a large percentage of oil refinery, petrochemical, and power generation plants throughout the world have been trying to reduce their operation cost by extending the service life of their critical machines, such as steam turbines, beyond the design life criteria. The key ingredient in plant life extension is Remaining Life Assessment Technology. This paper will outline the Remaining Life Assessment procedures, and review the various damage mechanisms such as creep, fatigue, creep-fatigue and various embrittlement mechanisms that can occur in these machines. Also highlighted will be the various testing methods for determining remaining life or life extension of components such as high precision STR (Stress Relaxation Test), which determines creep strength, and CDR (Constant Displacement Rate) Test, which evaluates fracture resistance. Other tests such as replication/microstructure analysis and toughness tests will also be reviewed for calculating the remaining life or life extension of the components. Use of the latest computer software will also be highlighted showing how creep-life, fatigue-life and creep/fatigue-life calculations can be performed. Also shown will be an actual life extension example of a hot gas expander performed in the field.

Remaining life assessment technology of machine equipment

2016 ◽  
Vol 2016 (0) ◽  
pp. 531
Author(s):  
Yoshiaki NISHINA ◽  
Daisuke IMANISHI ◽  
Yasuyuki KURIHARA
Keyword(s):  
Life Assessment ◽  
Remaining Life ◽  
Assessment Technology ◽  
Remaining Life Assessment

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.

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