This document summarizes a presentation about ASME B31.1 requirements for operation and maintenance (O&M) of piping systems from a code perspective. It discusses the history and organization of O&M requirements in the B31.1 code, including the addition of Chapter VII in 2007. It outlines the goals of O&M, including managing piping safety throughout its lifespan and conducting condition assessments. Examples of common pressure pipe failures that prompted improved O&M are also summarized, such as a desuperheater piping failure caused by thermal stresses known as the "banana effect".

1. ASME B31.1 Operation and
Maintenance Requirements-From
a Code Perspective
2014 IDEA Campus Workshop
Monte K. Engelkemier, P.E.

2. Agenda
• Organization of ASME B31.1
• History of O&M
• Goals of O&M
• Condition Assessment
• O&M Procedures
• Records
• A Common Pressure Failure Example: Banana
Effect

3. Organization of ASME B31.1 Committee
• Main Committee*
• Subgroups (Chapters & Appendices)
– General Requirements (CH I & IV, APP F-J)
– Design* (CH II, MA D, NMA II)
– Materials (CH III, MA A-C, NMA V)
– Fabrication & Examination (CH V & IV,
– Operation & Maintenance* (CH VII, NMA V)
– Special Assignments (Everything Else)
*Member
• Personally involved with ASME B31.1 Since 2006; currently the
Design and O&M Secretary; Member of the New FRP Code

4. History of B31.1 O&M

5. Acknowledgement
Joe Frey, P.E., one of the
driving forces behind the
scenes to get the initial
version of Chapter VII
into the 2007 Edition of
Code. Current Chairman
of B31.1.

6. Two Papers on the Subject
• EPRI 1018998 Guideline for Compliance to
B31.1 Chapter VII, Operation and
Maintenance
• ASME PVP-26069 High-Energy Piping Systems
are Now Covered Piping Systems

7. Chapter VII Operation &
Maintenance
• ASME B31.1 addresses the operation and
maintenance of power piping 2007 edition.
• The inspection and evaluations methods are
acknowledged, but not detailed.
• Wanted Owners to have a plan to address
O&M. It didn’t need to be a great plan, but
something was better than nothing.

8. APPENDIX V
• Predates Chapter VII
• Added to B31.1 after Mohave Failure 6/9/85
• Nonmandatory
• How to “maintain” critical piping
• Where details of condition assessment are
introduced into the Code
• Overtime portions of Appendix V are being
merged into Chapter VII

9. The W. A. Parish 8 CR Seam Weld Failure
Prompted Two Industry Reactions:
1. Seal welded cold reheat systems were added
to the inspection programs – fatigue cracks
2. ASME B31.1 Code Committee renewed
efforts on Appendix V and then began work
on a new mandatory operation and
maintenance chapter. Chapter VII was
published in December of 2007.

10. Other ASME Codes with
O&M Requirements
• B31.4 – 2002 Pipeline Transportation Systems
For Liquid Hydrocarbons and Other Liquids
(Chapter VII)
• B31.8 – 2003 Gas Transmission And Distribution
Systems (Chapter V)
• B31.11 – 2002 Slurry Transportation Piping
Systems (Chapter VII)
• High Pressure System HPS 2003 (Section 5000)

11. “Thou Shall
Know the Condition of
Thy Condition”
-Piping Gods (Before We Knew it was Round
with a Hole)
Goals of B31.1 O&M

12. GENERAL
• Managing safe pipe service begins with the
initial project concept and continues
throughout the service life of the system.
• Any new failure reinforces this protocol.

13. OPERATION AND MAINTENANCE
PROCEDURES
• The Operating Company shall be responsible
for the safe operation and maintenance of
their power piping.

14. Covered piping systems (CPS): Piping
systems on which condition assessments
are to be conducted:
• NPS 4 and larger MS, HRH, CRH, &
BFW
• NPS 4 and larger in other systems that
operate above 750F or above 1025 psi.
• The Operating Company may, in its
judgment, include other piping
systems determined to be hazardous
by an engineering evaluation of
probability and consequences of
failure.

15. Condition Assessment

16. CONDITION ASSESSMENT
OF CPS
• A condition assessment shall be performed
periodically based on condition.
• What is a good period?
– 3 Years
– 5 Years
– 10 Years

17. Basis for determining extent of
assessment and re-inspection
interval
Consideration of the age of the CPS, the
previous documented condition, anticipated
operating conditions.
This includes remaining life assessment.

18. O&M Procedures

19. OPERATION AND MAINTENANCE
PROCEDURES (Who is Doing This?)
• Operation of piping system within design limits
• Documentation of system operating hours and
hot, warm, and cold starts
• Documentation of actual operating
temperatures and pressures
• Documentation of system excursions including
pipe hammers
• Documentation of modifications and repairs to
CPS
• Document hydro pinning requirements

20. OPERATION AND MAINTENANCE
PROCEDURES
• Maintenance of pipe supports
• Maintenance of piping system vents, drains, and
relief valves
• Maintenance of steam attemperators
• Assessment of deteriorating mechanisms
including; creep, fatigue, corrosion, erosion
• Documentation of condition of CPS
• Maintenance of CPS

21. Records

22. RECORDS
• The condition assessment reports and any
reference documents, such as procedures
required by para. 139, drawings and reports,
shall be maintained and accessible for the life
of the plant.

23. RECORDS
• System name
• Material specification
• Design temperature and pressure
• Operating temperature and pressure
• Design diameter and wall thickness
• Operating hours, both total and since last
annual report
• Hot, warm, and cold starts, both total and since
last annual report

24. RECORDS
• Pipe support hot and cold walk down readings and
conditions, both past and current
• List of CPS dynamic events including hammers and
slugs.
• Hydro test pinning requirements
• Modifications and repairs
• Summary of pipe system inspection findings,
including list of areas of concern
• Recommendations for re-inspection interval and
scope

25. RECORDS (recommended)
• Actual pipe wall thickness and OD
• Fabrication and erection welding information
such as material, process, and PWHT used.
• Fabrication Repair history
• Final Weld Adjustments Actual Measurements
i.e. Cold Pull

26. Utility Plant/Unit Date Structure Time in Type of Failure
Service
Gulf States Sabine 1979 HRH bend
120,000 hrs
Catastrophic
(creep)
Utilities Unit 1
So. Cal. Mohave 1985 HRH horiz.
spool 88,000 hrs
Catastrophic
(creep)
Edison Unit 2
Detroit Edison Monroe 1986 HRH horiz.
spool 97,000 hrs
Catastrophic
(creep)
Unit 1
Virginia Pwr Surry Unit 2 1986 BF Elbow
13 years
Catastrophic
(FAC)
Gulf States Utilities Sabine 1992 HRH bend
212,000 hrs
Through-wall
leak (creep)
Unit 2
Alabama Pwr (Southern
Co)
Gaston 1992 SH Link
156,000 hrs
Through-wall
leak (creep)
Unit 5
Tampa Electric Gannon 1993 CRH horz
Bend 150,000 hrs
Catastrophic
(fatigue)
Unit 6
Failures Driving O&M

27. Utility Plant/Unit Date Structure Time in Type of Failure
Service
Wisconsin Electric Pleasant Prairie
Unit 1
1995 BF tee branch
15 years
Catastrophic
(FAC)
East Kentucky
Power
Spurlock Unit 2 1996 SH Link
~125,000 hrs
Through-wall
leak (creep)
Virginia Power Mt. Storm Unit
1
1996 SH Link
~200,000 hrs
Catastrophic
(creep)
Kansas City Hawthorne
Unit 5
1998 SH Link
~225,000 hrs
Catastrophic
(creep)P & L
Texas Genco W A Parish 2003 CRH horiz
spool 145,000 hrs
Catastrophic
(fatigue)Unit 8
Kansai Elec Pwr
Co
Mihama 2004 FW before
185000 hrs
Catastrophic
Unit 3 D/a (FAC)
Kansas City Iatan 2007 Desuperheater
piping 27 years
Catastrophic
(FAC)P & L

28. Desuperheater Supply Piping Failure
Failure occurred between gate valve & elbow
**THIS IS NOT A CONTROL VALVE, IT IS OPEN OR CLOSED**
Before After

29. A Common Pressure Failure Example:
Banana Effect
• What happens when a Desuperheater is
used too much?

30. Piping Layout
Anchor
Anchor
Steam
Source and
DSH to 150
PSIG
Saturated
Paper Mill
Flow
Element
Short Distance before
first elbow
Internals
ended up in
a Paper Mill
Strainer
Basket

31. Grout busted loose
from the water
hammer

32. Notice Crack in soil
around pier. The
crack was observed
to be about 1 ½ to 2
inches wide

33. Thermal Gradient
During Operation
LHot (Toperating)
LCold (Toperating)
During Shutdown
LCold = LHot at Toperating
LCold ≠ LHot at 70 F

34. The Big Effect
• Piping not uniformly heated causing:
– Supports to lift off
– Permanent Deformation of the Piping
– Almost killing workers

35. Spring
Topped Off

36. Support lifts up so let’s shim it! Not
once, not twice, but three or four
times.

37. Let’s shim here too.

38. Flow Element popped up
~24”, shearing the last bolts.
Eventually coming to rest 8”
above intended elevation.
Notice the sledge
hammer.

39. There was one worker on
either side of the pipe, if
pipe goes left or right
they’re dead.

40. Recommendations
• Better control of DSH
• Return supports to their original design
• Bolt-up new Flanged Element in a stress free
state, cut and miter existing 45 run to
accomplish this
• Perform NDE to determine if the whole system
should be replaced in a future shutdown
• Reevaluate System Drains

41. How it was Fixed
• Spring Cans were returned to
their original setting, shims were
used to take-up the gap.
• The 45 degree section shown,
was cut and mitered to take up
the offset caused. (ONE TIME FIX)
• Next time, replace the system.

42. Thank-you!
Questions???
Contact Information:
Monte K. Engelkemier, P.E.
engelkemierm@stanleygroup.com
563-264-6641 work