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Tata Projects
Quality Services-AIM
Date: 03-02-2016
1. Scope of coverage
2. Definition of deliverables
3. Roles and responsibilities
4. Methodology- Condition assessment & Re...
Scope: Condition Assessment & RLA
1. Industrial risk:
a. Identify: Damage mechanism
b. Assessment- Condition Assessment & ...
Definition of Deliverables
Recommendations :
- Maintain in operation as is / Re-rate
- For Repair
- Replace
- Inspection p...
5
Methodology
Inputs from Plant / Client
Review of Design Data & Inputs
a)If authentic design data is available
b)If Not,R...
6
Methodology
Inspection Data Analysis , evaluation & calculations
use as is, Repair, alteration and rerating
Planning of ...
7
1. General and local Metal loss
2. Surface connected cracking
3. Subsurface cracking
4. Micro fissuring/micro void forma...
8
1. Internal Inspection
2. On-stream inspection
3. External Inspection
4. Thickness inspection
5. Corrosion under insulat...
9
1.Fluorescent or dye penetrant examination
2.Magnetic Particle Examination
3.Radiographic Examination
4.Ultrasonic thick...
10
1. Corrosion rate determination
2. Remaining life calculation
3. Maximum allowable working pressure determination
4. Co...
11
Case Study
Remaining Life Assessment
of Pressure vessels
12
Nitrogen Pressure Vessels
Received an Order from
Ambuja Cement for the
Residual Life Assessment of
Pressure vessels
13
Nitrogen Pressure Vessels
Name of Manufacturer M/S MVS Engineering Ltd
Position Vertical
Dimensions
Dia 2.3 MTS x 10.7 ...
14
Case Study
Condition Assessment of
KVK Nilachal Thermal power plant
Capacity: 1 x 350 MW
15
Condition Assessment: Structural Stability
S. No. Area of Assessment
1 Boiler Pressure parts:
Boiler Drum,
Super heater...
16
Condition Assessment: Structural Stability
Sl.
No.
Civil: Area of Assessment
1 Turbine Generator Building
2 Chimney
3 M...
17
Condition Assessment: Structural Stability
18
Materials Analysis and Examination
19
7/19/2006
ULTRASONIC EXAMINATION
SCANNING DETAIL SHEET
SCANNING DETAIL
MH-3 (24” Manhole)
ID: 610mm
Thk: 105mm
Pad Plat...
Condition Assessment & RLA –Benefits
Plan of Action
22
References for Guideline
ASME Section V – NDT
ASME Section VIII Division I latest edition - Design & NDT
Acceptance
ASM...
23
THANK Q
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Aim condition assessment (2)

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Aim condition assessment (2)

  1. 1. Tata Projects Quality Services-AIM Date: 03-02-2016
  2. 2. 1. Scope of coverage 2. Definition of deliverables 3. Roles and responsibilities 4. Methodology- Condition assessment & Remaining life assessment. 5. Case studies 6. Plan of action- proof of concept, phases, scaling methodology and repeat of RLA cycle (long term engagement). TABLE OF CONTENTS
  3. 3. Scope: Condition Assessment & RLA 1. Industrial risk: a. Identify: Damage mechanism b. Assessment- Condition Assessment & RLA c. Periodic Inspection at regular intervals
  4. 4. Definition of Deliverables Recommendations : - Maintain in operation as is / Re-rate - For Repair - Replace - Inspection plan
  5. 5. 5 Methodology Inputs from Plant / Client Review of Design Data & Inputs a)If authentic design data is available b)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
  6. 6. 6 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
  7. 7. 7 1. General and local Metal loss 2. Surface connected cracking 3. Subsurface cracking 4. Micro fissuring/micro void formation 5. Metallurgical changes 6. Blistering 7. Dimensional Changes 8. Material properties changes Modes of deterioration and Failure
  8. 8. 8 1. Internal Inspection 2. On-stream inspection 3. External Inspection 4. Thickness inspection 5. Corrosion under insulation Types of inspection & Surveillance
  9. 9. 9 1.Fluorescent or dye penetrant examination 2.Magnetic Particle Examination 3.Radiographic Examination 4.Ultrasonic thickness measurement 5.Alternating current flux leakage examination 6.Eddy current examination 7.Field metallographic replication 8.Thermography 9.Pressure testing 10.Advanced NDT (PAUT, LRUT & TOFD) 11.Free run Tests Examination technique
  10. 10. 10 1. Corrosion rate determination 2. Remaining life calculation 3. Maximum allowable working pressure determination 4. Condition assessment 5. Rerating of equipment. Inspection Data Analysis & Evaluation
  11. 11. 11 Case Study Remaining Life Assessment of Pressure vessels
  12. 12. 12 Nitrogen Pressure Vessels Received an Order from Ambuja Cement for the Residual Life Assessment of Pressure vessels
  13. 13. 13 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
  14. 14. 14 Case Study Condition Assessment of KVK Nilachal Thermal power plant Capacity: 1 x 350 MW
  15. 15. 15 Condition Assessment: Structural Stability S. No. Area of Assessment 1 Boiler Pressure parts: Boiler Drum, Super heater tubes Reheater tubes Economiser tubes Headers Water wall panels 2 Boiler Structure 3 Boilers Structural Parts 4 Equipment : Bowl mill Hopper 5 ESP Structures erected
  16. 16. 16 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
  17. 17. 17 Condition Assessment: Structural Stability
  18. 18. 18 Materials Analysis and Examination
  19. 19. 19 7/19/2006 ULTRASONIC EXAMINATION SCANNING DETAIL SHEET SCANNING DETAIL MH-3 (24” Manhole) ID: 610mm Thk: 105mm Pad Plate: 60mm View from I nside MH10 Length: 22 mm (* ) (* * ) (Trans) Depth: 2mm (case 8) MH11 Length: 20mm Depth: 17mm (case 7 or 8) MH12 Length: 22 mm (* ) (* * ) (Trans) Depth: 2mm (case 7) MH01 Length: 70mm Depth: 38mm (Case 7) MH02 Length: 22 mm (* ) (Trans) Depth: 2mm (case 7) MH03 Length: 22 mm(* )(Trans) Depth: 3mm (case 7) MH04 Length: 30mm Depth: 3mm MH05 Length: 50mm Depth: 10mm (case 8) MH06 Two indications 40 mm & 170 mm (Does not appear to be cracks, weld groove side wall-TWI) MH08 Length: 180mm Depth: 27mm (Case 9a) MH09 Length: 22 mm (* ) (Trans) Depth: 4mm Weld Weld MH7a Length 55 mm (established by visual and PT) MH07b Length: 20 mm Depth: 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
  20. 20. Condition Assessment & RLA –Benefits
  21. 21. Plan of Action
  22. 22. 22 References for Guideline ASME Section V – NDT ASME Section VIII Division I latest edition - Design & NDT Acceptance ASME FFS 1- Fitness for service API 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 service API 580-Risk Based Inspection API 581 –Risk based inspection Technology API 653 -Tank Inspection, Repair, Alteration, and Reconstruction
  23. 23. 23 THANK Q

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