Condition Assessment Audit for Steam Plants

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" colspan=2 height=100 BGCOLOR="#CCCCFF" TEXT="#080000" bgproperties="fixed" background="0d200640egdysm.jpg"> <div> <FONT SIZE="6" COLOR="#000066" FACE="Arial" ><B>Jonas, Inc.</B></FONT><FONT SIZE="5" COLOR="#000099" FACE="Arial" ><B> </B></FONT><FONT SIZE="1" COLOR="#000099" FACE="Arial" ><B>   </B></FONT><B> |     </B><A HREF="index.htm" TARGET="_top" TITLE="Jonas, Inc."><U><B>Home</B></U></A><B> </B><B> </B><B>   </B><B> |    </B><A HREF="contact.htm" TARGET="_top" TITLE="Contact Us"><U><B>Contact Us</B></U></A><B>                                           </B></div> <div> back to<B>  </B><A HREF="services.htm" TARGET="_top" TITLE="Services"><U><B>Services</B></U></A><B> </B><B> </B><B> |  </B><B> </B><A HREF="audit.htm" TARGET="_top" TITLE="Plant Audit Water Chemistry and Corrosi"><U><B>Water Chemistry and Corrosion Control Plant Audit</B></U></A><FONT SIZE="3" COLOR="#000099" FACE="Arial" ><B>  </B><B>                                                                                   </B></FONT></div> <div> </div> </td> </tr><tr> <td valign="top" width=155 BGCOLOR="#0000BF" TEXT="#F7F7FF"> <div> <A HREF="analysis.htm" TARGET="_top" TITLE="Failure and Root Cause Analysis"><U>Failure and Root Cause Analysis</U></A></div> <div> <A HREF="boiler_tube.htm" TARGET="_top" TITLE="Boiler Tube Failure Analysis"><U>Boiler Tube Failure Analysis</U></A></div> <div> <A HREF="audit.htm" TARGET="_top" TITLE="Plant Audit Water Chemistry and Corrosi"><U>Plant Audit - Water Chemistry and Corrosion Control</U></A></div> <div> <A HREF="blade_design.htm" TARGET="_top" TITLE="Steam Turbine Blade Path Design and Anal"><U>Steam Turbine Blade Path Design and Analysis</U></A></div> <div> <A HREF="blade.htm" TARGET="_top" TITLE="Steam Turbine Blade Path Audit"><U>Steam Turbine Blade Path Audit</U></A></div> <div> <B><IMG BORDER="0" SRC="Symb075c00b700c8ffcccc00.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Condition Assessment Audit for Steam Plants</B></div> <div> <A HREF="online.htm" TARGET="_top" TITLE="Online Consulting on Corrosion and Water"><U>On-line Consulting on Corrosion and Water Chemistry</U></A></div> <div> <A HREF="expert.htm" TARGET="_top" TITLE="Expert Witness for Litigations and Insur"><U>Expert Witness for Litigations and Insurance Claims</U></A></div> <div> <A HREF="ndt.htm" TARGET="_top" TITLE="Remaining Life and NDT Interval"><U>Remaining Life and NDT Interval</U></A></div> <div> <A HREF="ec.htm" TARGET="_top" TITLE="Evaluation of ErosionCorrosion"><U>Evaluation of Erosion-Corrosion</U></A></div> <div> <A HREF="cavitation_service.htm" TARGET="_top" TITLE="Cavitation Detection and Monitoring"><U>Cavitation Detection and Monitoring</U></A></div> <div> <A HREF="sample_design.htm" TARGET="_top" TITLE="Design of Sampling Systems for Steam and"><U>Design of Sampling Systems for Steam and Water</U></A></div> <div> <A HREF="reliability.htm" TARGET="_top" TITLE="Managing Reliability"><U>Managing Reliability</U></A></div> <div> <A HREF="solutions.htm" TARGET="_top" TITLE="Common Corrosion and Water Chemistry Pro"><U>Common Corrosion and Water Chemistry Problems and Solutions</U></A></div> <div> <A HREF="steam_turbine.htm" TARGET="_top" TITLE="Steam Turbine and Piping Corrosion and C"><U>Steam Turbine and Piping Corrosion and Chemistry</U></A></div> <div> <A HREF="carry_over.htm" TARGET="_top" TITLE="Determination of Boiler Carryover"><U>Determination of Boiler Carry-over</U></A></div> <div> <A HREF="preheater.htm" TARGET="_top" TITLE="Troubleshooting, Inspection, and Root Ca"><U>Troubleshooting, Inspection, and Root Cause Analysis of Air Preheater Problems</U></A></div> <div> <A HREF="trouble.htm" TARGET="_top" TITLE="Troubleshooting Solutions"><U>Troubleshooting Solutions</U></A></div> <div> <A HREF="combustion_turbines.htm" TARGET="_top" TITLE="Combustion Turbines"><U>Combustion Turbines</U></A></div> <bR> </td> <td valign="top" height=380 BGCOLOR="#FFFFFF" TEXT="#080000"> <div> <B>Condition Assessment Audit of Steam Plants</B></div> <div> A 3 to 4 day plant audit to evaluate the state of the main cycle components and piping, assess remaining life and fitness for service, and recommend inspection and life extension activities.  This audit is typically the first step of plant-wide condition assessment and component life evaluation for the non-electrical systems.  Utility and industrial steam plants and related equipment.  </div> <div> <I><B>Note:</B></I>  The <A HREF="audit.htm" TARGET="_top" TITLE="Plant Audit Water Chemistry and Corrosi"><U>Water Chemistry and Corrosion Control Plant Audit</U></A> can be performed during the same plant visit.  </div> <div> <B>Objectives</B></div> <div> The objectives of the audit are:</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Safety assurance of the mechanical equipment - main cycle components</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Minimizing forced outages and maintenance costs </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Operation at best achievable efficiency (heat rate)</div> <div> <B>Background </B></div> <div> Increasing equipment life leads to more frequent forced outages, higher maintenance costs, and safety problems.  The cost of these problems can be up to $10,000 of lost electric production and $1 million a day of lost industrial production.</div> <div> The <U>main cycle components</U>, condition of which deteriorates with time, include:</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Boilers (waterwall tubes, superheater, reheater, headers)</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">High temperature piping</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Feedwater piping</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Turbines</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Deaerators</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Heaters and other auxiliary equipment</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Condensers</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Valves</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Steam Traps</div> <bR> <div> The <U>safety related damage mechanisms</U> are:  </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Creep</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Low Cycle Corrosion Fatigue (LCCF)</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Thermal (low cycle) Fatigue</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">High Cycle Corrosion Fatigue (HCCF)</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Stress Corrosion Cracking</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Flow-Accelerated Corrosion</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Cavitation</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Water Hammer</div> <bR> <div> Technology exists to properly inspect equipment, determine the damage mechanisms and root cause, and repair or replace the damaged components.  </div> <div> The <U>safety issues</U> experienced in steam systems are shown in the table below:</div> <bR> <div> <TABLE BORDER="2" CELLPADDING="1" CELLSPACING="1" WIDTH="576" BORDERCOLORLIGHT="#C0C0C0" BORDERCOLORDARK="#808080" FRAME="BOX" RULES="ALL" ALIGN="BOTTOM" HSPACE="0" VSPACE="0" > <tR> <tD VALIGN=CENTER HEIGHT= 47 ><NOBR><div> <B>Component</B></div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="135"><div> <B>Damage Mechanism [1]</B></div> </tD> <tD VALIGN=CENTER><NOBR><div> <B>Major Influences [2]</B></div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="90"><div> <B>Destructive Failures [3]</B></div> </tD> <tD VALIGN=CENTER><NOBR><div> <B>$ </B><B>Impact [4]</B></div> </NOBR></tD> </tR> <tR> <tD VALIGN=CENTER ROWSPAN=3 HEIGHT= 37 ><NOBR><div> Steam Piping</div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="135"><div> Creep</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Welds, temperature, time</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER ROWSPAN=3 WIDTH="75"><div> 10^7</div> </tD> </tR> <tR> <tD VALIGN=CENTER WIDTH="135"><div> LCF, LCCF</div> </tD> <tD VALIGN=CENTER><NOBR><div> Temperature changes</div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="90"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="16" ALIGN="bottom" WIDTH="90" HSPACE="0" VSPACE="0"></tD> </tR> <tR> <tD VALIGN=CENTER WIDTH="135"><div> Carbon steel graphitization</div> </tD> <tD VALIGN=CENTER><NOBR><div> Temperature and time</div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="90"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="33" ALIGN="bottom" WIDTH="90" HSPACE="0" VSPACE="0"></tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 33 WIDTH="101"><div> Drums and Headers</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> LCF, LCCF, SCC</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Temperature cycling, design, water chemistry</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> N</div> </tD> <tD VALIGN=CENTER WIDTH="75"><div> 10^7</div> </tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 33 WIDTH="101"><div> Boiler Tubes</div> </tD> <tD VALIGN=CENTER><NOBR><div> LCCF (20 others)</div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="145"><div> Water chemistry, cycling, heat flux, etc. </div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> N</div> </tD> <tD VALIGN=CENTER WIDTH="75"><div> 10^5</div> </tD> </tR> <tR> <tD VALIGN=CENTER ROWSPAN=4 HEIGHT= 16 WIDTH="101"><div> Feedwater and </div> <div> Wet Steam Piping</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> FAC</div> </tD> <tD VALIGN=CENTER><NOBR><div> Design, water chemistry</div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER ROWSPAN=4 WIDTH="75"><div> 10^7</div> </tD> </tR> <tR> <tD VALIGN=CENTER WIDTH="135"><div> Cavitation</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Design, operation</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> </tR> <tR> <tD VALIGN=CENTER WIDTH="135"><div> SCC</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Residual stress, chemistry</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> N</div> </tD> </tR> <tR> <tD VALIGN=CENTER WIDTH="135"><div> CF, LCCF</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Weld quality, water chemistry, temperature changes</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> N</div> </tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 66 WIDTH="101"><div> Deaerator, Flash Tank, Hot Water and Steam Vessels - Welds</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> CF, SCC</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Design (water piston), residual welding stress, operation, water chemistry</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER WIDTH="75"><div> 10^7</div> </tD> </tR> <tR> <tD VALIGN=CENTER ROWSPAN=2 HEIGHT= 66 WIDTH="101"><div> LP Turbine Rotors and Disks</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> SCC</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Design stresses, temperaturen, high strength steel, steam chemistry</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER ROWSPAN=2 WIDTH="75"><div> 10^7</div> </tD> </tR> <tR> <tD VALIGN=CENTER WIDTH="135"><div> CF</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Steam chemistry, design, vibration</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> N</div> </tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 49 WIDTH="101"><div> LP Turbine Blades</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> CF</div> <div> SCC</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Steam chemistry, design vibration, pitting, erosion,</div> <div> High strength steel</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> N</div> </tD> <tD VALIGN=CENTER WIDTH="75"><div> 10^6</div> </tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 33 WIDTH="101"><div> HP/IP Turbine Rotors</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> LCF</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Cycling, inclusions, fatigue design</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER WIDTH="75"><div> 10^7</div> </tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 49 WIDTH="101"><div> Turbine</div> </tD> <tD VALIGN=CENTER><NOBR><div> Destructive Overspeed</div> </NOBR></tD> <tD VALIGN=CENTER WIDTH="145"><div> Steam chemistry (boiler carry-over) - sticking valves</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER><NOBR><div> 10^7 - 10^8</div> </NOBR></tD> </tR> <tR> <tD VALIGN=CENTER HEIGHT= 49 WIDTH="101"><div> Turbine</div> </tD> <tD VALIGN=CENTER WIDTH="135"><div> Rubbing</div> </tD> <tD VALIGN=CENTER WIDTH="145"><div> Steam chemistry, deposits, thrust bearing wear, thermal expansion</div> </tD> <tD VALIGN=CENTER WIDTH="90"><div> Y</div> </tD> <tD VALIGN=CENTER WIDTH="75"><bR> <div> 10^6</div> <bR> </tD> </tR> </TABLE></div> <bR> <div> <TABLE BORDER="0" CELLPADDING="2" CELLSPACING="1" WIDTH="520" BORDERCOLORLIGHT="#C0C0C0" BORDERCOLORDARK="#808080" FRAME="BOX" RULES="ALL" ALIGN="BOTTOM" HSPACE="0" VSPACE="0" > <tR> <tD VALIGN=TOP HEIGHT= 80 WIDTH="27"><div> [1]</div> </tD> <tD VALIGN=TOP WIDTH="482"><div> CF - Corrosion Fatigue               </div> <div> LCF - Low Cycle Fatigue                   </div> <div> LCCF - Low Cycle Corrosion Fatigue          </div> <div> SCC - Stress Corrosion Cracking              </div> <div> FAC - Flow-Accelerated Corrosion         </div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 19 WIDTH="27"><div> [2]</div> </tD> <tD VALIGN=TOP><NOBR><div> Age influences the degree of damage for all issues except the last two</div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="27"><div> [3]</div> </tD> <tD VALIGN=TOP WIDTH="482"><div> At least one destructive failure during the last 30 years </div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="27"><div> [4]</div> </tD> <tD VALIGN=TOP WIDTH="482"><div> Lost production and repairs per one event</div> </tD> </tR> </TABLE></div> <div> <I><B>Audit Description</B></I></div> <div> Based on the industry experience and plant information gathered in advance and during the plant visit, critical components and their potential damage mechanisms are identified, existing inspection, maintenance, and operation practices are evaluated, and the needs for improvements and more detailed life evaluation and extension determined.</div> <bR> <div> The audit is structured as follows:</div> <bR> <div> <TABLE BORDER="0" CELLPADDING="2" CELLSPACING="1" WIDTH="508" BORDERCOLORLIGHT="#C0C0C0" BORDERCOLORDARK="#808080" FRAME="BOX" RULES="ALL" ALIGN="BOTTOM" HSPACE="0" VSPACE="0" > <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="22"><div> 1.</div> </tD> <tD VALIGN=TOP WIDTH="475"><div> Information gathering - prior to visit</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="22"><div> 2.</div> </tD> <tD VALIGN=TOP WIDTH="475"><div> Cycle and equipment design review - prior to visit</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="22"><div> 3.</div> </tD> <tD VALIGN=TOP WIDTH="475"><div> Initial meeting - ~ 2 hours</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="22"><div> 4.</div> </tD> <tD VALIGN=TOP WIDTH="475"><div> Review of plant experience - ~ 6 hours</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 32 WIDTH="22"><div> 5.</div> </tD> <tD VALIGN=TOP><NOBR><div> Review of operation, maintenance, NDT, water chemistry and corrosion control - </div> <div> ~ 2 days</div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="22"><div> 6.</div> </tD> <tD VALIGN=TOP><NOBR><div> Preliminary Conclusions and Recommendations - provided before leaving the site</div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 33 WIDTH="22"><div> 7.</div> </tD> <tD VALIGN=TOP WIDTH="475"><div> Closing meeting:  a joint review of the Preliminary Conclusions and Recommendations - ~ 2 hours</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="22"><div> 8.</div> </tD> <tD VALIGN=TOP WIDTH="475"><div> Audit Report - ~ 6 weeks after plant visit</div> </tD> </tR> </TABLE></div> <bR> <bR> <bR> <DIV ALIGN="LEFT"></DIV> <div> <IMG SRC="1e266430.gif" border=0 width="358" height="67" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <bR> </td> </tr></table></body>