Presented by: Charlie Rutan Formally Senior Engineering Advisor for LyondellBasell
Fixed Equipment Inspection, Repair, and Failure Analysis Houston, Texas October 14, 2010
Special Acknowledgements
Michael Guillot, Ph.D., P.E. Stress Engineering
Services, Inc.; mike.guillot@stress.com
Contents of Presentation
Repairs made at every plant to keep things
running, but considered as temporary repairs by API or other governing bodies
Flange Repair
10 mm (0.4 inches) Pressure limitations Immediate off-the-truck repair Excessive peening must be avoided to prevent bolts from being overloaded
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Mechanical Clamp Repair (continued) Hot Tapping can be performed through mechanical clamps. This is a very effective way of preventing a crack to propagate.
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Hot Tap
Hot Tapping Line Stops
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On-Line Weld Repairs (continued) In some cases these repairs can be considered permanent repairs. Allow clamp to come to line temperature Use the proper welding procedure
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On-Line Weld Repairs Welding Procedures (continued) Process conditions are key and will define the welding criteria TIG welding is preferred for the first 3 or 4 passes. A 3/32 diameter weld rod should be used for the next 3 to 4
Note: on the inside of a 6 pipe with a wall thickness of 0.280 the wall temperature was measured to be 740oF with the TIG heat area of .39 in2 while the 3/32 diameter weld rod had the same temperature but the area was increased 1.83 times from 0.39 in2 to 0.95 in2
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API 510 8.1.5.1 Temporary Repairs 8.1.5.1.1 General Temporary repairs should be removed and replaced with suitable permanent
repairs at next available maintenance opportunity. Temporary repairs may remain in place for a longer period of time only if evaluated, approved, and documented by engineer and inspector.
Location of temporary repair Specific details, e.g., material of construction, thickness, size of welds, NDE
performed Details of analyses performed Requirements for future inspections Due date for installing permanent repair
Inspection plans shall include monitoring integrity of temporary repair until permanent repairs are complete
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API 570 7.6 Reporting and Records for Piping System Inspection Any significant increase in corrosion rates shall be reported to
owner/user for appropriate action (Change in process conditions) Owner/user shall maintain appropriate permanent and progressive records of each piping system covered by API 570. These records shall contain pertinent data such a
Piping system service Classification Identification numbers Inspection intervals Documents necessary to record name of individual performing testing, date,
types of testing, results of thickness measurements and other tests, inspections, repairs (temporary and permanent), alterations, or rerating.
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API 570 8.1.3 Welding Repairs (including on-stream) 8.1.3.1 Temporary Repairs For temporary repairs, including on-stream, a full encirclement
welded split sleeve or box-type enclosure designed by piping engineer may be applied over damaged or corroded area. Longitudinal cracks shall not be repaired in this manner unless piping engineer has determined that cracks would not be expected to propagate from under the sleeve. In some cases, piping engineer will need to consult with a fracture analyst. If repair area is located (for example, pitting or pinholes) and specified minimum yield strength (SMYS) of the pipe is < 40 ksi (276 MPa), a temporary repair may be made by fillet welding a properly designed split coupling or plate patch over pitted area. Material for the repair shall match base metal unless approved by piping engineer.
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API 570 8.1.3 Welding Repairs (including on-stream) 8.1.3.1 Temporary Repairs (contd.) For minor leaks, properly designed enclosures may be welded over
the leak while piping system is in service, provided inspector is satisfied that adequate thickness remains near weld, and piping component can withstand welding without likelihood of further material damage, such as from caustic service. Temporary repairs should be removed and replaced with a suitable permanent repair at next available maintenance opportunity. Temporary repairs may remain in place for a longer time only if approved and documented by piping engineer.
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