Material Degradation of Steam Pipe Elbow after Long-Term Exposure

2015 ◽  
Vol 647 ◽  
pp. 162-169
Author(s):  
Lenla Pekařová ◽  
Zdeněk Kuboň
Keyword(s):  
Residual Life ◽  
Creep Damage ◽  
Life Extension ◽  
Metallographic Analysis ◽  
Material Degradation ◽  
Pipe Surface ◽  
Pipe Elbow ◽  
Toughness Testing ◽  
Steam Pipe ◽  
Stable Growth

Routine non-destructive examination of the steam pipe elbow after more than 240 000 hours of operation at elevated temperature revealed the extensive creep damage on the outer surface of the pipe elbow. Complex metallographic analysis made in this area confirmed creep damage as well as the non-uniform nature of the cavitation. The density of cavities continuously decreased from the outer pipe surface towards the inner surface, but also its density rapidly waned beyond the damaged area in both directions, along the circumference as well as the length of the elbow. The actual extent of the material degradation was then evaluated by testing of mechanical properties, Charpy-V and fracture toughness testing and the results were used in calculation of the residual life of the pipe elbow. It was shown that although the creep damage was perhaps one of the worst detected in Czech Republic, the cracks in the pipe elbow would spread by the stable growth until the half of the pipe wall thickness. This result thus confirms the possibility of creep life extension far beyond the limit criteria used so far.

Comparative Analysis of Creep Cavitation Damage in 0.5Cr-0.5Mo-0.3V Steel after Long-Term Creep Exposure by Metallography and Replica Testing

2017 ◽  
Vol 891 ◽  
pp. 335-340
Author(s):  
Zdeněk Kuboň ◽  
Lenka Pekařová ◽  
Jana Kosňovská ◽  
Pavel Poštulka
Keyword(s):  
Outer Surface ◽  
Creep Damage ◽  
Metallographic Analysis ◽  
Pipe Surface ◽  
Cavitation Damage ◽  
Pipe Elbow ◽  
Creep Cavitation ◽  
Term Creep ◽  
Parallel Evaluation

Complex metallographic analysis was performed on the steam pipe elbow made of 0.5Cr-0.5Mo-0.3V steel after long-term (more than 240 000 hours) of operation at elevated temperature that revealed the extensive creep damage on the outer surface of the pipe elbow. Metallographic analysis confirmed pronounced creep damage at the outer surface but, at the same time, the non-uniform nature of the cavitation. The density of cavities continuously decreased from outer to inner pipe surface in the most damaged area and rapidly waned along the circumference as well as the length of the elbow. Parallel evaluation of actual extent of the cavitation damage made by metallography and replica methods in various parts of the pipe elbow confirmed that replica method is capable to describe and quantify the cavitation damage of this steel in the same way as metallography, including evaluation of creep damage according to Nordtest NT TR 302.

Evaluation of Residual Life of Existing Offshore Platforms in Western Offshore, India

2021 ◽  
Author(s):  
A. Renugadevi ◽  
S. Nallayarasu ◽  
S. Karunanithi
Keyword(s):  
Residual Life ◽  
Probability Of Failure ◽  
Oil Field ◽  
Life Extension ◽  
Offshore Platforms ◽  
Strength Assessment ◽  
Encounter Probability ◽  
Reliability Method ◽  
Reserve Strength ◽  
Extension Period

Abstract Western offshore oil field in India has nearly 300 offshore platforms for oil and gas exploration, of which almost 50% of platforms have outlived their life. Life extension of these platforms has become essential for further production activities. In many cases, design level analyses combined with ultimate strength assessment, life extension has been granted. However, risk-based assessment based on the probability of failure based on available reserve strength linked to additional life extension could be a logical method. The Reserve Strength Ratio (RSR) is defined as a ratio of reserve capacity of the jacket structure and the design level environmental loads (1 year or 5year or 10 year or 100-year return period). The encounter probability of these design storms for the life extension period has been established probability for the extension period has been used as a threshold to determining the required RSR using the probability of collapse. For the present study, four typical aged wellhead platforms with different water depths are selected, and RSR is evaluated by carrying out push over analysis. The Monte Carlo Simulation method is used to generate the statistical values of RSR. The probability of failure is then calculated by First Order Reliability Method (FORM) using MATLAB for different RSR values. Reassessment criteria for the existing offshore platforms have been described from the reliability analysis results based on probability failure and encounter probability.

Parametric Investigation on the Effect Factors for Liquid Droplet Impingement Erosion

2011 ◽  
Author(s):  
Rui Li ◽  
Hisashi Ninokata ◽  
Michitsugu Mori
Keyword(s):  
Power Plants ◽  
Erosion Rate ◽  
Structural Integrity ◽  
Volume Fraction ◽  
Liquid Droplet ◽  
Droplet Velocity ◽  
Life Extension ◽  
Droplet Impingement ◽  
Pipe Surface ◽  
Bent Pipe

Liquid droplet impingement (LDI) erosion could be regarded to be one of the major causes of unexpected troubles occasionally occurred in the inner bent pipe surface. Evaluating the LDI erosion is an important topic of the thermal hydraulics and structural integrity in aging and life extension for nuclear power plants safety. In order to investigate the effect of various parameters, such as droplet diameter, droplet velocity and injected droplet number, on the erosion rate induced by LDI, droplet impingement under different conditions are conducted numerically by a two-phase computational approach. Considering the carrier turbulence kinetic energy attenuation due to the involved droplets, numerical simulations have been performed by using two-way vapor-droplet coupled system. This computational fluid model is built up by incompressible Reynolds Averaged Navier-Stoke equations using standard k-ε model and the SIMPLE algorithm, and the numerical droplet model adopts the Lagrangian approach, a general LDI erosion prediction procedure for bent pipe geometry has been performed to supplement an available CFD code. A correlation for the erosion rate in terms of droplet velocity, diameter and volume fraction is purposed for the engineers’ maintenance reference. Based on our computational results, comparison with an available accident data was made to prove that our methodology could be an appropriate way to simulate and predict the bent pipe wall thinning phenomena.

Codes and Standards for Managing Degradation of Boilers in Service

2020 ◽  
Author(s):  
Corrado Delle Site ◽  
Emanuele Artenio ◽  
Gennaro Sepede ◽  
Matteo Chini ◽  
Francesco Giacobbe
Keyword(s):  
Service Time ◽  
Power Plants ◽  
Residual Life ◽  
Creep Damage ◽  
Pressure Vessels ◽  
Steam Boilers ◽  
Critical Components ◽  
Set Up ◽  
Effective Use ◽  
Life Consumption

Abstract Degradation of pressure equipment is becoming an important issue due to increasing asset service time in process and power plants across Europe. For this reason it is important to assess life consumption of these assets to avoid catastrophic failures. Therefore it is necessary to refer to national/international normative on this subject. At present time the Italian thermotechnical committee (CTI) has drawn up a comprehensive set of norms which help the user to set up an inspection plan to investigate and assess degradation of pressure vessels and boilers. In the first part of this paper creep damage of Steam Generators is analyzed. For this purpose results of INAIL (Istituto Nazionale per l’ Assicurazione contro gli Infortuni sul Lavoro) database of steam boilers with 100’000 service hours or more is illustrated. Critical components are identified with reference to materials, geometry and operating parameters (pressure, temperature and time). At the end of the design life cycle, components of pressure equipment operated in creep regime must subjected to specific checks to estimate their residual life and the suitability for further use in safety conditions. The procedure allows to define reinspection intervals keeping acceptable the risk associated with the further use of the component related to creep even in evidence of defects in progress. The first check must be performed after 100,000 hours of effective use. Then, residual life evaluations must be repeated according to period of time that are defined as function of the results of all the checks carried out. In the second part of this paper boiler degradation is discussed with reference to NDT results and in-field inspection campaigns which are carried out traditionally after 45 years of service time, to minimize the risk of pressure components failures. In this paper results of different case studies are discussed with reference to degradation mechanisms and applicable standards.

On-Line Health Monitoring Research on T-Joint of Main Steam Piping

2013 ◽  
Vol 330 ◽  
pp. 549-552 ◽  
Author(s):  
J.H. Jia ◽  
H.C. Zhang ◽  
X.Y. Hu ◽  
L.P. Cai ◽  
S.T. Tu
Keyword(s):  
High Temperature ◽  
Power Plant ◽  
Residual Life ◽  
Thermal Power ◽  
Creep Damage ◽  
Piping System ◽  
Main Challenge ◽  
On Line ◽  
Main Steam ◽  
Creep Monitoring

The main challenge of long-time creep monitoring on site is a reliable sensor. In this paper, a sensing device is developed specifically for high temperature creep monitoring. And it is applied to on-line monitor the strain of material on T-joint of main steam piping. Its reliability is verified theoretically using the finite element method and experimentally by high temperature on site test. The creep damage of the T joint is evaluated basing on the creep rate sensed by the sensing device. And the residual life is predicted for the piping system using the Monkman-Grant equation. This system is useful for safety assessment procedures in thermal power plant, nuclear power plant and petrochemical industries.

Interpretation of damage mechanics behaviour of two-bar structures for the life extension of high-temperature components

2003 ◽  
Vol 38 (2) ◽  
pp. 125-132 ◽  
Author(s):  
S-T Tu ◽  
X Ling
Keyword(s):  
High Temperature ◽  
Damage Mechanics ◽  
Creep Damage ◽  
Life Extension ◽  
Continuum Damage ◽  
Basic Model ◽  
Different Dimensions ◽  
Damage Theory ◽  
High Temperature Components

The creep damage behaviour of two-bar structures of different dimensions and materials is studied in terms of continuum damage theory. The basic model is used to interpret the effectiveness of life extension measures for complicated structures. It is found that replacement of the more damaged component prior to rupture will result in an optimized life extension efficiency, depending on the geometric or material difference between the damaged and less damaged components. This has potential to provide guidance on the effectiveness of life extension repairs in high-temperature plants.

Degradation Evaluation of 2.25Cr-1Mo Steel Using Nondestructive Method

2005 ◽  
Vol 297-300 ◽  
pp. 1951-1957
Author(s):  
Jong Seo Park ◽  
Un Bong Baek ◽  
Jeong Min Kim ◽  
Seung Hoon Nahm ◽  
Bong Young Ahn
Keyword(s):  
Electrical Resistivity ◽  
Ultrasonic Attenuation ◽  
Indentation Test ◽  
Creep Damage ◽  
Nondestructive Method ◽  
Magnetic Characteristics ◽  
Isothermal Heat Treatment ◽  
Material Degradation ◽  
Aging Parameter ◽  
Degradation Evaluation

Several nondestructive evaluation methods were attempted for the estimation of the creep damage of degraded 2.25Cr-1Mo steel. The specimens of three different aging periods were prepared by an isothermal heat treatment at 430°C, 482°C, and 515°C. The effect of probe configuration on the electrical resistivity was studied. Single configuration method and dual-configuration method were utilized for measuring electrical resistivity. The electrical resistivity was determined by a standard DC four-point probe method at 24±0.5°C. Indentation test, magnetic characteristics test and ultrasonic test were carried out to investigate the correlation between the major characteristics and aging parameter. Unlike the electrical resistivity characteristics, ultrasonic attenuation coefficient and indentation characteristics did not show a relation to Larson-Miller parameter. However, a correlation between the electrical resistivity and aging parameter was identified, which allows one to estimate the extent of material degradation.

Dynamic Fracture Toughness and Charpy Transition Properties of a Service-Exposed 2.25Cr-1Mo Reheater Header Pipe

2003 ◽  
Vol 125 (2) ◽  
pp. 227-233 ◽  
Author(s):  
P. R. Sreenivasan ◽  
C. G. Shastry ◽  
M. D. Mathew ◽  
K. Bhanu Sankara Rao ◽  
S. L. Mannan ◽  
...  
Keyword(s):  
Fracture Toughness ◽  
Dynamic Fracture ◽  
Prolonged Exposure ◽  
Residual Life ◽  
Shear Fracture ◽  
Temper Embrittlement ◽  
Dynamic Fracture Toughness ◽  
Life Extension ◽  
Virgin Material ◽  
Fracture Appearance Transition Temperature

Residual life analysis of power plant components like boiler tubes, superheater outlet headers, reheater headers, steam pipes, etc., is important for life extension and avoidance of catastrophic failure. In this context, fracture toughness is very important. The fracture characteristics after prolonged exposure to high temperatures and pressures are likely to be different from that of the virgin material. 2.25Cr-1Mo reheater header pipe exposed at 813 K for 120,000 h was studied by instrumented impact tests (IIT) to evaluate dynamic fracture toughness and Charpy transition properties. The methods presented in this paper for estimating dynamic fracture toughness from IIT of Charpy specimens give reliably conservative results without the need for precracking. For estimating fracture appearance transition temperature (FATT) from IIT load-time traces, the equation for percent shear fracture, PSF3, gives the best 1:1 correlation with measured values from fracture surfaces. The lower bound equation for variation of fracture toughness with temperature derived in the present study is higher than that obtained from the FATT master curve (FATT-MC) approach. Comparison of Charpy indices like FATT and upper-shelf energy for the service exposed steel to results for the virgin material reported in the literature and the compositional J-Factor estimates for temper-embrittlement susceptibility indicate that the present steel, even after 120,000 h exposure to high temperature service, has probably undergone only very little or nil degradation in toughness properties.

Life Extension of the Fast Breeder Test Reactor

2010 ◽  
Author(s):  
B. Anandapadmanaban ◽  
A. Babu ◽  
B. Babu ◽  
K. Dinesh ◽  
V. Ramanathan ◽  
...  
Keyword(s):  
Residual Life ◽  
Reactor Power ◽  
Life Assessment ◽  
Life Extension ◽  
Periodic Safety ◽  
Grid Plate ◽  
Residual Life Assessment ◽  
Test Reactor ◽  
Ageing Management ◽  
Equipment Qualification

The Fast Breeder Test Reactor (FBTR) is a loop type sodium cooled fast reactor located at Kalpakkam, India. The reactor went critical in October, 1985 with a core of 23 unique high Plutonium carbide fuel subassemblies and the reactor power was rated for 10.5MWt with peak linear heat rating of fuel at 320W/cm. The extension of the target burn-up of this fuel based on Post Irradiation Examination at different stages enabled progressive expansion of the core and increase in reactor power. The reactor has been operated upto a power level of 18.6MWt/3MWe with a sodium temperature of 482°C max. The reactor has completed 24 years of operation and is currently under periodic safety review by the Atomic Energy Regulatory Board of India. As a part of the periodic safety review, equipment qualification status and ageing management studies have been presented to the regulators. Equipment qualification refers to the ability of the replaceable equipment to meet the functional requirements on demand, accomplished by periodic surveillance, maintenance and replacement. Ageing management addresses the residual life assessment of components which are passive, non-replaceable / replaceable with difficulty, taking into account their life degrading mechanisms. Over a period of time, based on the operational feedback, maintenance difficulties and obsolescence, several major components have been replaced. These include the Neutronic channels, UPS, computers of the Central Data Processing System, main boiler feed pumps, three control rod drive mechanisms, two control rods, central canal plug, deaerator lift pumps, reheaters of the steam water system, station batteries, DM plant and Nitrogen plant. The starting air system of the emergency diesel generators and isolation dampers of the reactor containment building have also been replaced. Regarding the non-replaceable components, residual life assessment has been carried out based on the operational history vis-a`-vis the design limits for each component. The life limiting mechanism of heat transport systems of FBTR are creep and fatigue. Since the reactor has operated only upto a temperature of 444°C till 2007, the creep effect is insignificant. The total number of thermal cycles seen by the reactor components as of 2007 was 163, as against the design cycle of 2000 for most of the components. Hence all the heat transport system components are as good as fresh ones. However, the major life limiting factor has been found to be the Neutronic fluence on the grid plate which supports the core. The fast flux at the grid plate location was measured using Np foils and the residual life of the reactor has been assessed to be 10.5 effective full power years. This paper details the life extension exercise being carried out for FBTR.

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