Tata ProjectsQuality Services-AIM

Date: 03-02-2016

1. Scope of coverage2. Definition of deliverables3. Roles and responsibilities 4. Methodology- Condition assessment & Remaining

life assessment.5. Case studies6. Plan of action- proof of concept, phases, scaling

methodology and repeat of RLA cycle (long term engagement).

TABLE OF CONTENTS

Scope: Condition Assessment & RLA 1. Industrial risk: a. Identify: Damage mechanism b. Assessment- Condition Assessment & RLA c. Periodic Inspection at regular intervals

Definition of Deliverables

Recommendations :

- Maintain in operation as is / Re-rate

- For Repair

- Replace

- Inspection plan

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Methodology

Inputs from Plant / Client

Review of Design Data & Inputsa)If authentic design data is availableb)If Not,Reverse Engineering will be done to establish the design data with pre-bid inspection survey.

Team Of Experts for Pre BID Inspection Survey Involves –1. Design Engg. 2. Inspection Expert 3. Static Eqpt. Expert 4. NDT Expert 5. Corrosion Expert

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Methodology

Inspection Data Analysis , evaluation & calculations

use as is, Repair, alteration and rerating

Planning of Site Visit – Inspection, Examination and Testing

Recommendations on RLA & Condition Assessment

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1. General and local Metal loss2. Surface connected cracking3. Subsurface cracking4. Micro fissuring/micro void formation5. Metallurgical changes6. Blistering7. Dimensional Changes8. Material properties changes

Modes of deterioration and Failure

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1. Internal Inspection2. On-stream inspection3. External Inspection4. Thickness inspection5. Corrosion under insulation

Types of inspection & Surveillance

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1.Fluorescent or dye penetrant examination2.Magnetic Particle Examination3.Radiographic Examination4.Ultrasonic thickness measurement5.Alternating current flux leakage examination6.Eddy current examination7.Field metallographic replication8.Thermography9.Pressure testing10.Advanced NDT (PAUT, LRUT & TOFD)11.Free run Tests

Examination technique

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1. Corrosion rate determination2. Remaining life calculation3. Maximum allowable working pressure

determination4. Condition assessment5. Rerating of equipment.

Inspection Data Analysis & Evaluation

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Case Study Remaining Life Assessment

of Pressure vessels

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Nitrogen Pressure Vessels

Received an Order from Ambuja Cement for the Residual Life Assessment of Pressure vessels

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Nitrogen Pressure Vessels

Name of Manufacturer M/S MVS Engineering Ltd

Position Vertical

Dimensions Dia 2.3 MTS x 10.7 MTRS Length ,Shell 25mm thick and Dish 25 mm thick

Material Carbon Steel

Drawing No. CL-223

Date on which first taken in use 2005

Safe Working Pressure Recommended by manufacturer

25 kg/cm2

Date of last Examination 17/10/2011

Date of last NDT Examination 17/10/2011

Date of last Hydro Test Record 04/04/2011

Safe Working Pressure 25 Kg/sqcm

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Case Study Condition Assessment of

KVK Nilachal Thermal power plant

Capacity: 1 x 350 MW

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Condition Assessment: Structural Stability S. No. Area of Assessment

1 Boiler Pressure parts: Boiler Drum,Super heater tubesReheater tubesEconomiser tubesHeadersWater wall panels

2 Boiler Structure

3 Boilers Structural Parts

4 Equipment : Bowl millHopper

5 ESP Structures erected

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Condition Assessment: Structural Stability Sl.

No.Civil: Area of Assessment

1 Turbine Generator Building

2 Chimney

3 Mill Foundation

4 Boiler Feed Pump foundation

5 ESP control Room

6 PA & FD Fan duct support foundation

7 ID fan foundation

8 Electrical Control Room

9 Power house building

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Condition Assessment: Structural Stability

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Materials Analysis and Examination

197/19/2006

ULTRASONIC EXAMINATION SCANNING DETAIL SHEET

SCANNING DETAIL

MH-3 (24” Manhole) ID: 610mmThk: 105mmPad Plate: 60mm

View from Inside

MH10Length: 22 mm (*) (**) (Trans)Depth: 2mm (case 8)

MH11Length: 20mmDepth: 17mm (case 7 or 8)

MH12Length: 22 mm (*) (**) (Trans)Depth: 2mm (case 7)

MH01Length: 70mmDepth: 38mm (Case 7) MH02

Length: 22 mm (*) (Trans)Depth: 2mm (case 7)

MH03Length: 22 mm(*)(Trans)Depth: 3mm (case 7)

MH04Length: 30mmDepth: 3mm

MH05Length: 50mmDepth: 10mm (case 8)

MH06 Two indications 40 mm & 170 mm (Does not appear to be cracks, weld groove side wall-TWI)MH08

Length: 180mmDepth: 27mm (Case 9a)

MH09 Length: 22 mm (*) (Trans)Depth: 4mm

Weld

WeldMH7aLength 55 mm (established by visual and PT)

MH07bLength: 20 mmDepth: Through wall established by UT (Case 9b)

MH07 Crack is visible from outside at weld going towards 60 mm tapered area (Case 9b).

75 mm

Note: The depth of crack in 55 mm length in weld and tapered section could not be established. The reason is anticipated skewing of the beam or possibly attenuate the ultrasound altogether.

Length: 31 mm as seen in photo

(*) Length from weld width

(**) MH10 & 12 as too close from MH11

30mm

20mm

Rev 01

Condition Assessment & RLA –Benefits

Plan of Action

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References for GuidelineASME Section V – NDTASME Section VIII Division I latest edition - Design & NDT Acceptance ASME FFS 1- Fitness for serviceAPI 510-Press.Vessel Inspection code (Insp,rating,repair & alteration)API 570-Piping Insp.( Inspection, rating, repair & alteration of in process piping)API 579 –Fitness for serviceAPI 580-Risk Based InspectionAPI 581 –Risk based inspection TechnologyAPI 653 -Tank Inspection, Repair, Alteration, and Reconstruction

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THANK Q