Creep Relaxation Behavior of High-Energy Piping

2000 ◽  
Vol 122 (4) ◽  
pp. 488-493 ◽  
Author(s):  
Raymond K. Yee ◽  
Marvin J. Cohn
Keyword(s):  
Stress Relaxation ◽  
Thermal Loading ◽  
Elevated Temperatures ◽  
Three Dimensional ◽  
Creep Damage ◽  
High Energy ◽  
External Loading ◽  
Piping System ◽  
Dead Weight ◽  
Piping Systems

The analysis of the elastic stresses in high-energy piping systems is a routine calculation in the power and petrochemical industries. The American Society of Mechanical Engineers (ASME) B31.1 Power Piping Code was developed for safe design and construction of pressure piping. Postconstruction issues, such as stress relaxation effects and selection of maximum expected creep damage locations, are not addressed in the Code. It has been expensive and time consuming to evaluate creep relaxation stresses in high energy piping systems, such as main steam and hot reheat piping. After prolonged operation of high-energy piping systems at elevated temperatures, it is very difficult to evaluate the redistribution of stresses due to dead weight, pressure, external loading, and thermal loading. The evaluation of stress relaxation and redistribution is especially important when nonideal conditions, such as bottomed-out or topped-out hangers, exist in piping systems. This paper uses three-dimensional four-node quadrilateral shell elements in the ABAQUS finite element code to evaluate the time for relaxation and the nominal relaxation stress values for a portion of a typical high-energy piping system subject to an ideally loaded hanger or to an overloaded hanger. The stress relaxation results are evaluated to suggest an approximation using elastic stress analysis results. [S0094-9930(00)01304-4]

Ranking of Creep Damage in Main Steam Piping System Girth Welds Considering Multiaxial Stress Ranges

2016 ◽  
Vol 138 (4) ◽  
Author(s):  
Marvin J. Cohn ◽  
Fatma G. Faham ◽  
Dipak Patel
Keyword(s):  
Creep Damage ◽  
High Energy ◽  
Sustained Load ◽  
Piping System ◽  
Multiaxial Stress ◽  
Analysis Model ◽  
Principal Stresses ◽  
Piping Systems ◽  
Girth Welds ◽  
Main Steam

A high-energy piping (HEP) asset integrity management program is important for the safety of plant personnel and reliability of the fossil plant generating unit. HEP weldment failures have resulted in serious injuries, fatalities, extensive damage of components, and significant lost generation. The main steam (MS) piping system is one of the most critical HEP systems. Creep damage assessment in MS piping systems should include the evaluation of multiaxial stresses associated with field conditions and significant anomalies, such as malfunctioning supports and significant displacement interferences. This paper presents empirical data illustrating that the most critical girth welds of MS piping systems have creep failures which can be successfully ranked by a multiaxial stress parameter, such as maximum principal stress. Inelastic (redistributed) stresses at the piping outside diameter (OD) surface were evaluated for the base metal of three MS piping systems at the piping analysis model nodes. The range of piping system stresses at the piping nodes for each piping system was determined for the redistributed creep stress condition. The range of piping stresses was subsequently included on a Larson–Miller parameter (LMP) plot for the grade P22 material, revealing the few critical (lead-the-fleet) girth welds selected for nondestructive examination (NDE). In the three MS piping systems, the stress ranges varied from 55% to 80%, with only a few locations at stresses beyond the 65 percentile of the range. By including evaluations of significant field anomalies and the redistributed multiaxial stresses on the outside surface, it was shown that there is a good correlation of the ranked redistributed multiaxial stresses to the observed creep damage. This process also revealed that a large number of MS piping girth welds have insufficient applied stresses to develop substantial creep damage within the expected unit lifetime (assuming no major fabrication defects). This study also provided a comparison of the results of a conventional American Society of Mechanical Engineers (ASME) B31.1 Code as-designed sustained stress analysis versus the redistributed maximum principal stresses in the as-found (current) condition for a complete set of MS piping system nodes. The evaluations of redistributed maximum principal stresses in the as-found condition were useful in selecting high priority ranked girth weldment creep damage locations. The evaluations of B31.1 Code as-designed sustained load stresses were not useful in selecting high priority creep damage locations.

The TransAlta High-Energy Piping Program—A Five-Year History

2000 ◽  
Vol 123 (1) ◽  
pp. 65-69 ◽  
Author(s):  
Marvin J. Cohn,
Keyword(s):  
Creep Damage ◽  
Analytical Techniques ◽  
High Energy ◽  
Management Plan ◽  
Piping System ◽  
Engineering Consulting ◽  
Piping Systems ◽  
Creep Fatigue ◽  
Sustained Loads ◽  
Selection Of

In 1995, the High-Energy Piping Strategic Management Plan (HEPSMP) was initiated at TransAlta Utilities Corporation (TAU) for the three generating facilities. At that time, it was recognized that several of the piping systems were exhibiting signs of creep relaxation, with some hangers bottomed or topped out online and/or offline. Previous hanger adjustment attempts were not always adequate. The program workscope included: 1) hot and cold piping system walkdowns, 2) selection of high-priority girth weld inspection locations, 3) examination of critical weldments, 4) weld repairs where necessary, 5) adjustments or modifications of malfunctioning steam line hangers, and 6) recommended work for future scheduled outages. Prior to 1996, examination locations were limited to the traditional locations of the terminal points at the boiler and turbine, with reexaminations occurring at arbitrary intervals. Since the terminal points are not necessarily the most highly stressed welds causing service-related creep damage, service damage may not occur first at the pre-1996 examined locations. There was a need to maximize the safety and integrity of these lines by ensuring that the highest risk welds were identified and given the highest priority for examination. An engineering consulting company was selected to prioritize the highest risk weldments for each piping system. This risk-based methodology included the prediction and evaluation of actual sustained loads, thermal expansion loads, operating loads, multiaxial stresses, creep relaxation, and cumulative creep life exhaustion. The technical process included detailed piping system walkdowns and application of advanced analytical techniques to predict and rank creep/fatigue damage for each piping system. TAU has concluded that the program has met its objective of successfully prioritizing inspection locations. The approach has also resulted in reducing the scope and cost of reexaminations. Phases 1 and 2 evaluations and examinations have been completed for all units. Results of some of the important aspects of this program are provided as case history studies.

Remaining Life of High-Energy Piping Systems Using Equivalent Stress

1990 ◽  
Vol 112 (3) ◽  
pp. 260-265 ◽  
Author(s):  
M. J. Cohn
Keyword(s):  
Equivalent Stress ◽  
Creep Damage ◽  
High Energy ◽  
Piping System ◽  
Term Operation ◽  
Flexibility Analysis ◽  
Multiaxial Stress State ◽  
Piping Systems ◽  
System Life ◽  
American Society

Fossil power plant high-energy piping systems operated at high temperatures are subject to creep damage, which is a time-dependent phenomenon. Traditional guidelines, such as the American Society of Mechanical Engineers (ASME) B31.1 Power Piping Code, were developed for plants having design lives in the 25–30 yr regime. Since many of these systems are being operated beyond 200,000 hr, it is important to reconsider the methodology of creep damage analysis to assure reliable long-term operation. Seven high-energy piping systems were evaluated in this study. The analysis of a minimum piping system life due to creep considered two approaches. The first approach used the traditional ASME B31.1 flexibility analysis guidelines. The second approach considered more detailed multiaxial stress state types of evaluations. The various equivalent stress methods used all six load components from the flexibility analysis. In nearly every case, the equivalent stress methods predicted significantly higher stresses. Consequently, the equivalent stress methodology results in 14 to 97 percent lower time to rupture values as compared to the values predicted using ASME B31.1 stresses.

Simplified Second Stage Creep/Relaxation Analysis of Moderately Complex Spatially Three-Dimensional Piping Systems

1974 ◽  
Vol 96 (3) ◽  
pp. 184-192 ◽  
Author(s):  
G. H. Workman ◽  
E. C. Rodabaugh
Keyword(s):  
Three Dimensional ◽  
Theoretical Development ◽  
Small Displacement ◽  
Piping System ◽  
Stress Strain ◽  
Curved Pipe ◽  
Thermal Change ◽  
Second Stage ◽  
Piping Systems ◽  
Applied Forces

An analysis technique for predicting the second stage creep/relaxation response of moderately complex spatially three-dimensional piping systems is presented herein. The theoretical development of this technique is based on two major assumptions. The first assumption is that at any time the behavior of the piping system can be associated with two components. One is an elastic component which is recoverable, and the other is a creep/relaxation component, which is not recoverable. The second major assumption, the simplifying assumption, is that the creep/relaxation strains due to axial, bending, and torsional loading can be decoupled and strains due to internal pressure can be neglected. Utilizing small displacement linear strain assumptions, the elastic stress-strain and creep/relaxation stress-strain rate laws can be integrated over the pipe’s cross section to yield generalized force-deformation relationships. The method of initial strains associated with the matrix displacement method of structural analysis is now applied to generate the solution of the creep/relaxation problem. This formulation utilizes two distinct types of piping elements. The first is a straight uniform pipe element and the second is a circularly curved pipe element, which incorporates both elastic and creep/relaxation flexibility factors. The end result of this formulation is a digital computer program capable of analyzing spatially three-dimensional piping systems under creep/relaxation conditions that can be represented by a series of straight or circularly curved pipe elements subjected to applied forces, displacements, and/or thermal change. An example analysis is included.

Pulsation suppression in a reciprocating compressor piping system using a two-tank element

2017 ◽  
Vol 232 (4) ◽  
pp. 427-437 ◽  
Author(s):  
Quyang Ma ◽  
Zhenhuan Wu ◽  
Guoan Yang ◽  
Yue Ming ◽  
Zheng Xu
Keyword(s):  
Theoretical Model ◽  
Three Dimensional ◽  
Flow Characteristics ◽  
Wave Theory ◽  
Damping Coefficient ◽  
Piping System ◽  
Pressure Pulsations ◽  
Surge Tank ◽  
Piping Systems ◽  
Gas Pulsations

Gas pulsations excited by reciprocating compressors could introduce severe vibrations and noise in piping systems. When pulsating gas flows through the reducers, the changes in flow characteristics, such as velocity and damping coefficient, will affect the pressure pulsations. To circumvent these constraints, a two-tank element is introduced to control the gas pulsation that is still strong in the piping system with a surge tank. Installing another surge tank to form a two-tank element is more flexible and costs lower than replacing the original surge tank with a larger one. In this work, a theoretical model based on the wave theory was proposed to study the transferring mechanism of gas pulsations in the pipeline with the two-tank element. By considering the damping coefficient and the Mach number, the distributions of the pressure pulsations were predicted by the theoretical model and agreed with the three-dimensional fluid dynamics transient analysis. Three experiments were conducted to prove that the suppression capability of the two-tank element is as good as that of a single-tank element (surge tank) with the same surge volume. The volume optimization of the two-tank element is implemented by selecting the best allocations of the two tanks’ volumes to achieve larger reductions of pressure pulsations. Assuming that the total surge volume is constant, we found that the smaller the volume of the front tank (near the cylinder) is, the lower the pulsation levels are. The optimized result proves that in some conditions the two-tank element could control pulsations better than the single-tank element with the same surge volume.

The Importance of High Energy Piping Support Maintenance to Enhance System Useful Life

2015 ◽  
Author(s):  
Samuel A. Huff ◽  
John P. Leach ◽  
Daniel S. Vail
Keyword(s):  
High Energy ◽  
Life Extension ◽  
Piping System ◽  
Support Design ◽  
Piping Systems ◽  
Proper Design ◽  
Useful Life ◽  
High Level ◽  
Extension Program

As part of the design basis of any piping system utilized to convey materials, pipe supports are required to ensure those pipes remain in their designed locations and do not overly expand or move due to sustained or occasional loads. These loads represent the total forces and moments in the piping components and as a result create stresses that affect the life of the component. Proper design and maintenance of these supports per the applicable codes and standards provide a reasonable life expectancy for the piping systems. This presentation will review the various codes and standards utilized for both pipe support design and maintenance. A high level overview of what information must be obtained to perform an analysis and meet ASME B31.1 Power Piping code requirements when modifying piping systems will be presented. Specific inputs to system design and computational software including material properties, stress intensification factors (SIF), thicknesses and tolerances, pressures, temperatures, insulation, coatings, the occasional loads, etc. will be discussed. Guidelines will be discussed for determining what piping modifications warrant a full pipe stress analysis to be performed. Recommendations for pipe support maintenance inspections will be provided to facilitate increased life expectancies of subject piping systems. The mandatory requirements of ASME B31.1 Chapter VII will be discussed, as well as recommendations from the non-mandatory appendix. Implementing maintenance programs at existing facilities will be discussed. Step by step recommendations for how to apply these guidelines within a long-term life extension program will be given. Tolerances and general guidelines associated with these programs will also be discussed. Finally, common pipe support failures, what they can affect, and how to look for early indicators of fatigue or failure will be covered.

Risk-Based Inspection Applied to Main Steam and Hot Reheat Piping Systems

2007 ◽  
Author(s):  
Marvin J. Cohn
Keyword(s):  
Cost Effective ◽  
High Energy ◽  
Accurate Estimate ◽  
Terminal Point ◽  
Rational Approach ◽  
Piping System ◽  
Piping Systems ◽  
Risk Areas ◽  
Main Steam ◽  
Life Consumption

Many utilities select critical welds in their main steam (MS) and hot reheat (HRH) piping systems by considering some combination of design-based stresses, terminal point locations, and fitting weldments. The conventional methodology results in frequent inspections of many low risk areas and the neglect of some high risk areas. This paper discusses the use of a risk-based inspection (RBI) strategy to select the most critical inspection locations, determine appropriate reexamination intervals, and recommend the most important corrective actions for the piping systems. The high energy piping life consumption (HEPLC) strategy applies cost effective RBI principles to enhance inspection programs for MS and HRH piping systems. Using a top-down methodology, this strategy is customized to each piping system, considering applicable effects, such as expected damage mechanisms, previous inspection history, operating history, measured weldment wall thicknesses, observed support anomalies, and actual piping thermal displacements. This information can be used to provide more realistic estimates of actual time-dependent multiaxial stresses. Finally, the life consumption estimates are based on realistic weldment performance factors. Risk is defined as the product of probability and consequence. The HEPLC strategy considers a more quantitative probability assessment methodology as compared to most RBI approaches. Piping stress and life consumption evaluations, considering existing field conditions and inspection results, are enhanced to reduce the uncertainty in the quantitative probability of failure value for each particular location and to determine a more accurate estimate for future inspection intervals. Based on the results of many HEPLC projects, the author has determined that most of the risk (regarding failure of the pressure boundary) in MS and HRH piping systems is associated with a few high priority areas that should be examined at appropriate intervals. The author has performed many studies using RBI principles for MS and HRH piping systems over the past 15 years. This life management strategy for MS and HRH critical welds is a rational approach to determine critical weldment locations for examinations and to determine appropriate reexamination intervals as a risk-based evaluation technique. Both consequence of failure (COF) and likelihood of failure (LOF) are considered in this methodology. This paper also provides a few examples of the application of this methodology to MS and HRH piping systems.

Elastic-Plastic Analysis of Thick-Walled Toroidal Pressure Vessels

2008 ◽  
Author(s):  
R. Adibi-Asl
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Three Dimensional ◽  
Pressure Vessels ◽  
Toroidal Shell ◽  
Piping System ◽  
Straight Pipe ◽  
Element Analysis ◽  
Process Industries ◽  
Piping Systems

Piping systems in process industries and nuclear power plants include straight pipe runs and various fittings such as elbows, miter bends etc. Elbows and bends in piping systems provide additional flexibility to the piping system along with performing the primary function of changing the direction of fluid flow. Distinctive geometry of these toroidal shell components result in a structural behavior different from straight pipe. Hence, it would be useful to predict the behavior of these components with acceptable accuracy for design purposes. Analytical expressions are derived for stresses set up during loading and unloading in a toroidal shell subjected to internal pressure. Residual stresses in the component are also evaluated. The proposed solutions are then compared with three-dimensional finite element analysis at different locations including intrados, extrados and flanks.

Dynamic Response Studies of Piping-Support Systems

1990 ◽  
Vol 112 (1) ◽  
pp. 39-45 ◽  
Author(s):  
T. Chiba ◽  
R. Koyanagi
Keyword(s):  
Dynamic Characteristics ◽  
Support Systems ◽  
Three Dimensional ◽  
Local Stress ◽  
Integrated Approach ◽  
Piping System ◽  
3 Dimensional ◽  
Piping Systems ◽  
Seismic Loadings ◽  
High Level

Considering the effect of the interaction between piping and support systems in the piping design is a more integrated approach to improve the reliability of piping systems. So, it is important to clarify the dynamic characteristics of the piping and the restraint structure during the seismic events. It may be desirable to investigate the effect of the gap on the response and the local stress of the piping systems. The dynamic characteristics of a simplified piping model with gaps was investigated by the tests and the analysis. Three-dimensional piping model test was performed to estimate the effect of the gap on the response of the piping system. It can be found that the local stress and the stiffness of the piping and the restraint structure under the seismic loadings should be considered in the seismic design. The gap size was not so effective on the response of the 3-dimensional piping system in the high-level response.

Three-Dimensional Modeling of Creep Damage in Airfoils for Advanced Turbine Systems

2008 ◽  
Author(s):  
Ventzislav G. Karaivanov ◽  
Danny W. Mazzotta ◽  
Minking K. Chyu ◽  
William S. Slaughter ◽  
Mary Anne Alvin
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Gas Turbines ◽  
Damage Mechanics ◽  
Thermal Loading ◽  
Three Dimensional ◽  
Creep Damage ◽  
Creep Model ◽  
Working Fluid ◽  
Element Analysis

Future oxy-fuel and hydrogen-fired turbines promise increased efficiency and low emissions. However, this comes at the expense of increased thermal load from higher inlet temperatures and a change in the working fluid in the gas path, leading to aero-thermal characteristics that are significantly different than those in traditional gas turbines. A computational methodology, based on three-dimensional finite element analysis (FEA) and damage mechanics is presented for predicting the evolution of creep in airfoils in these advanced turbine systems. Information revealed from three-dimensional computational fluid dynamics (CFD) simulations of external heat transfer and thermal loading over a generic airfoil provides detailed local distributions of pressure, surface temperature, and heat flux penetrating through the thermal barrier coated layer. There is an additional mechanical loading due to the centrifugal acceleration of the airfoil. Finite element analysis is then used to predict temperature and stress fields over the domain of the airfoil. The damage mechanics-based creep model uses a scalar damage parameter. This creep model is coupled with finite element analysis to predict the evolution of stress and creep damage over the entire airfoil. Visualization of the creep damage evolution over the airfoil shows the regions that are most susceptible to failure by creep.

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