ACME Chemicals: High Pressure Steam (HS) Piping

ACME Chemicals
Houston, TX
Report No.: N-24HS-PIPING

Inspector: Jeff Walling
Employer: Eagle Inspection
Inspection Date: 7/12/2010
IN-SERVICE
Inspection Report For
High Pressure Steam (HS) Piping

System ID: 36
Building 24
An API Standard 570 Inspection that included visual (VT) and ultrasonic
thickness (UT) examinations was conducted on the Building 24, HS piping system in
the ACME Chemical facility located at Houston, TX. This system was originally built
to ASME B31.1 construction code. This inspection was conducted in accordance
with requirements of the API-570 standard for inspections of in-service piping. The
following is a detailed report of the inspection including findings and
recommendations.
Inspector Signature
API Certification No. 341
Page 1
TABLE OF CONTENTS
1.0 EXECUTIVE SUMMARY
2.0 VESSEL DATA
3.0 INSPECTION RESULTS
3.1 Leaks
3.2 Misalignment
3.3 Vibration
3.4 Support
3.5 Corrosion
3.6 Insulation
3.7 Other
4.0 RECOMMENDATIONS
4.1 Leaks
4.2 Misalignment
4.3 Vibration
4.4 Support
4.5 Corrosion
4.6 Insulation
4.7 Other
5.0 ULTRASONIC THICKNESS MEASUREMENTS
5.1 Results
5.2 Recommendations
APPENDICIES
APPENDIX A
Mechancial Integrity Calculations
APPENDIX B
Thickness Measurement Record
APPENDIX C
API 570 Inspection Checklist
APPENDIX D
Inspection Drawings
APPENDIX E
Inspection Photographs
APPENDIX F
NDE Reports
APPENDIX G
P&ID's
Page 2
1.0 EXECUTIVE SUMMARY

An API Standard 570 inspection of the building 24 HS (main steam) circuit 36,
located at ACME Chemical in Houston, TX was conducted on 07/12 to
07/16/2010. This inspection was made to collect data in order to evaluate the
mechanical integrity and fitness for service of the system.
No major problems were noted during this inspection.
Discrepancies are listed in Section 3.0 Inspection Results and 4.0
Recommendations.
SYSTEM DESCRIPTION:
The HS steam system 36 provides high pressure steam to chiller turbines CH
24-1, CH 24-2 and CH 24-3 in building 24 and sub systems (MS and LS systems)
through manifolds and regulators for supplied steam to the utility systems in other
building (bldg 15, 2 , 3, et) via underground utility tunnels that run through out the
facility. The source of steam comes from four 500lb steam boilers located in
building 24.
HISTORICAL RECORDS:
Inspections in accordance with ACME Class 1 ratings (visual exams every year)
and RV bench tests (every two years) have been performed on this system
routinely for the past decade. No previous UT measurements on the piping
system were available
Next Inspection:
Next Visual inspection is due by:
7/13/2015
Next UT inspection is due by:
7/11/2020
Governing component limiting life:
034
Page 3
2.0 PIPING DATA
Service:
High Pressure Steam (HS) Piping
Circuit:
System ID: 36
Inspection Date:
7/12/2010
Build Date: (yr)
1960
Const Code:
ASME B31.1
Pipe Spec:
NA
Diameter (in.):
10", 6" & 3" Mains
Sup. Span (ft.):
20
Material Type:
Ferritic Steels
Flange Rating:
600
MAWP (psi):
520
Design Temp.: (F)
650
Oper. Press.: (psi)
450
Oper. Temp.: (F)
550
MDMT: (F)
-20
API Class:
Class 2
ASME Category:
Normal
Insulation Type:
Calcium Silicate (12.5lb ^3ft)
Insulation Thk.: (in) 3
Page 4
3.0 INSPECTION RESULTS

The following results are the summarization of a field checklist
that was utilized during the inspection of circuit System ID: 36
3.1 Leaks:
3.1.1 There were two steam leaks through mechanical joints (flange and
packing gland) found during this inspection (reference iso drawings #2 and
#3). One is located on the Boiler #4 isolation valve and one at the distribution
manifold on the North end in building 24.
3.1.2 There was water on the deck that appeared to be coming from the
insulation below the valve station on line 24-HS-3-CS-C2-4 that goes to
Chiller #2.
3.2 Misalignment:
3.2.1 No misalignment issues were noted at this inspection
3.3 Vibration:
3.3.1 No vibration issues were noted at this inspection.
3.4 Supports:
3.4.1 The line appears to be well supported. Much of the support structure
was hidden from view, however where they were visible no coating failure or
corrosion of the supports was observed.
3.5 Corrosion:
3.5.1 The piping is carbons steel, well insulated and operating at above 300F
and does not show signs of CUI or external corrosion.
3.6 Insulation:
3.6.1 The HS piping is insulated with 3" CalSil block insulation and appears to
be in satisfactory condition with minor breaks and openings through out the
system.
3.7 Other:
3.7.1 None
Page 5
4.0 RECOMMENDATIONS
4.1 Leaks:
4.1.1 Make efforts to repair the two steam leaks through mechanical joints
(reference iso drawings #2 and #3) by tightening the packing gland,
repacking, and/or replacing gasket as necessary.
4.1.2 Strip insulation from valve station on line 24-HS-3-CS-C2-4 that goes
to Chiller #2 and check for possible steam leak in mechanical joints or other
source of water from under insulation and make repairs as needed.
4.2 Misalignment:
4.2.1 None
4.3 Vibration:
4.3.1 None.
4.4 Supports:
4.4.1 None.
4.5 Corrosion:
4.5.1 None
4.6 Insulation:
4.6.1 Make repairs to insulation were needed through out the system to
restore 100% coverage.
4.7 Other:
4.7.1 None
4.8 Next Inspection:

4.8.2 Next Visual inspection is due by
7/13/2015
4.8.3 Next UT inspection is due by
7/11/2020
4.8.4 Governing component limiting life
034
Page 6
5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS
5.1 Results Summary:

5.1.1 UT ports were required to be cut into the insulation to facilitate the UT
examination of the HS piping system as designated by the API-Inspector. All
Thickness measurements were above that required by ASME B31.1 Power
Piping code requirements. All points examined have greater than twenty
years remaining life with results showing moderate internal erosion-corrosion
of the piping wall.
5.2 Recommendations:
5.2.1 Re-inspect piping system in 10 years in accordance with API-570
recommendations for Class II piping.
Page 7
APPENDIX A
Mechancial Integrity Calculations
1) Corrosion Rates
2) Remaining Life Calculations
3) Minimum Required Thickness Calculations
4) Structural Required Thickness Calculations
Page 8
API-570 PIPING EVALUATION

PIPE COMPONENT REMAINING LIFE
Report No
Client
Inspector
Circuit
Date
N-24HS-PIPING
ACME Chemical
Jeff Walling
System ID: 36
7/12/2010
Minimum Thickness Determinations:

a) The following pipe minimum thicknesses are based on the current inhouse engineering standards, which take into consideration, pressures,
structural integrity and localized corrosion allowance.
Size
<=2"
3"
4"
6"
8"
10"
12"
>12"
t min
0.100
0.100
0.100
0.100
0.125
0.125
0.156
0.156
b) Large size pipe components or components subject to high

pressures are calculated per the applicable construction code (i.e.,
ASME B31.3, para. 304 as follows: PD/2(SE+PY) = t)
Pipe Component Remaining Life Calculations:
CML
Line No.
001
002
24-HS-6-CS-B2-1
24-HS-6-CS-B3-1
003
004
Size Sch
6
6
80
80
24-HS-6-CS-B3-1
80
24-HS-6-CS-B3-1
80
005
24-HS-6-CS-B4-2
006
24-HS-6-CS-B4-2
007
008
Age
t prev t act t min
Ca
Cr
RL
0.432
0.432
0.454 0.143
0.304 0.143
0.311
0.161
0
0.00256
>20
63
50
0.432
0.281 0.143
0.138
0.00302
46
50
0.432
0.299 0.143
0.156
0.00266
59
80
50
0.432
0.438 0.143
0.295
>20
80
50
0.432
0.682 0.143
0.539
>20
24-HS-6-CS-B4-2
24-HS-6-CS-B4-2
6
6
80
80
50
50
0.432
0.432
0.428 0.143
0.301 0.143
0.285
0.158
8.0E-05
0.00262
>20
60
009
24-HS-6-CS-MSH-3
80
50
0.432
0.426 0.143
0.283
0.00012
2358
010
24-HS-10-CS-MSH-3
10
40
50
0.365
0.416 0.162
0.254
>20
011
24-HS-10-CS-MSH-3
10
40
50
0.365
0.403 0.162
0.241
>20
012
013
24-HS-10-CS-MSH-3
24-HS-10-CS-MSH-3
10
10
40
40
50
50
0.365
0.365
0.357 0.162
0.377 0.162
0.195
0.215
0.00016
0
1216
>20
014
24-HS-10-CS-MSH-3
10
40
50
0.365
0.321 0.162
0.159
0.00088
180
015
24-HS-10-CS-MSH-4
10
40
50
0.365
0.375 0.162
0.213
>20
016
24-HS-10-CS-MSH-4
10
40
50
0.365
0.367 0.162
0.205
>20
017
24-HS-10-CS-MSH-4
10
40
50
0.365
0.368 0.162
0.206
>20
018
019
24-HS-10-CS-MSH-4
24-HS-10-CS-MSH-4
10
10
40
40
50
50
0.365
0.365
0.462 0.162
0.261 0.162
0.300
0.099
0
0.00208
>20
47
020
24-HS-6-CS-BP-4
80
50
0.432
0.382 0.143
0.239
0.001
239
021
24-HS-10-CS-MSH-4
10
40
50
0.365
0.260 0.162
0.098
0.0021
46
022
24-HS-6-CS-MSH-4
80
50
0.432
0.424 0.143
0.281
0.00016
1756
023
24-HS-6-CS-MSH-4
80
50
0.432
0.424 0.143
0.281
0.00016
1756
Report No.:
50
50
N-24HS-PIPING
Page 9
Pipe Component Remaining Life Calculations:

CML
Line No.
024
24-HS-6-CS-MSH-4
025
Size Sch
6
80
24-HS-6-CS-BP-4
80
026
24-HS-6-CS-MSH-4
027
24-HS-6-CS-MSH-4
028
24-HS-6-CS-MSH-4
029
030
Age
t prev t act t min
Ca
Cr
RL
0.432
0.404 0.143
0.261
0.00056
466
50
0.432
0.377 0.143
0.234
0.0011
213
80
50
0.432
0.403 0.143
0.260
0.00058
448
80
50
0.432
0.413 0.143
0.270
0.00038
711
80
50
0.432
0.282 0.143
0.139
0.003
46
24-HS-6-CS-MSH-4
24-HS-3-CS-C3-4
6
3
80
80
50
50
0.432
0.300
0.396 0.143
0.223 0.158
0.253
0.065
0.00072
0.00154
351
42
031
24-HS-3-CS-C3-4
80
50
0.300
0.276 0.158
0.118
0.00048
246
032
24-HS-3-CS-C2-4
80
50
0.300
0.239 0.158
0.081
0.00122
66
033
24-HS-3-CS-C2-4
80
50
0.300
0.235 0.158
0.077
0.0013
59
034
035
24-HS-3-CS-C2-4
24-HS-3-CS-C1-4
3
3
80
80
50
50
0.300
0.300
0.211 0.158
0.240 0.158
0.053
0.082
0.00178
0.0012
30
68
036
24-HS-3-CS-C1-4
80
50
0.300
0.250 0.158
0.092
0.001
92
037
24-HS-6-CS-B5-2
80
50
0.432
0.495 0.143
0.352
>20
038
24-HS-6-CS-B5-2
80
50
0.432
0.478 0.143
0.335
>20
039
24-HS-6-CS-B5-2
80
50
0.432
0.540 0.143
0.397
>20
040
041
24-HS-6-CS-MSH-4
24-HS-10-CS-MSH-3
6
10
80
40
50
50
0.432
0.365
0.591 0.143
0.352 0.162
0.448
0.190
0
0.00026
>20
729
Report No.:
50
N-24HS-PIPING
Page 10
PIPE COMPONENT PRESSURE CALCULATIONS
Date
7/14/2010
ASME B31.1 104.1
Client:$&0(&KHPLFDO
Circuit
Project No.:
Line No. 24-6-HS-CS-BP
36
24HS-PIPING
Material
A 106
MAWP
S.H.
Prod. SG
Temp.
Size
Sch
tnom
Ca
520
0.01
650
80
0.432
0.331
Internal Pressure Minimum Thickness Calcs

Y
520.0 Design Pressure, psi
P
D
6.625
PD/2(SE+PY) = t
0.40 Coefficient
Outside Diameter, in.
17000 Stress, psi
Joint Efficiency
0.100
Minimum Thickness, in.
External Pressure Minimum Thickness Calculations

L
Effective Length, in.
Do
L/Do
X-Chart
Do/t
Factor from Figure G

Stress Value
Pa
External Pressure, psi
Internal Pressure Calculations

t = tnom - Ca =
2SEt/D-2tY = P
0.101 Thickness, in.
524.7
External Pressure Calculations

t
L/Do
Do/t
4B/3(Do/t) = Pa
A
Thickness, in.
X-Chart

Cylinder Capacities
lb's of Prod lb's of

Cu Ft Gals Water S.G. Prod.
4.525 33.9 282.21 0.01
2.8
Plate Data
Metal Material Catagory
Sq Ft Cu in CS/Crom. Stl
40.57 2521.5 0.2833 lbs/cu in
Project No.: 24HS-PIPING
Stress Value
Pa
2.881 Shell Radius, in.

0.432 Shell Thickness, in
5836.8
Variables for Capacities

300 Shell Length, in.
Sq In
Internal Pressure, psi
Author: JLW
Page 11
Total lb's
lb's of
Steel
714.3
Prod + Steel
717
Page 1 of 3
Circuit
Line No. 24-3-HS-CS-C1
36
Material
A 106
MAWP
S.H.
Prod. SG
Temp.
Size
Sch
tnom
Ca
520
0.01
650
80
0.300
0.200
PD/2(SE+PY) = t
0.40 Coefficient
520.0
Design Pressure, psi
3.5
17000 Stress, psi
Joint Efficiency
0.053

L
Do
L/Do
X-Chart
Do/t

Stress Value
Pa

t = tnom - Ca =
2SEt/D-2tY = P
994.2

t
L/Do
Do/t
4B/3(Do/t) = Pa
A
Thickness, in.
X-Chart

Cylinder Capacities

1.147 8.58 71.511 0.01
0.7
Plate Data
20.96 904.78 0.2833 lbs/cu in
Stress Value
Pa
3015.9

Sq In
Author: JLW
Page 12
Total lb's
lb's of
Steel
256.3
Prod + Steel
257
Page 2 of 3
Circuit
Line No. 24-10-HS-CS-MSH Material
36
A 106
MAWP
S.H.
Prod. SG
Temp.
Size
Sch
tnom
Ca
520
0.01
650
10
40
0.365
0.202
PD/2(SE+PY) = t
0.40 Coefficient
520.0
Design Pressure, psi
10.75
17000 Stress, psi
Joint Efficiency
0.162

L
Do
L/Do
X-Chart
Do/t

Stress Value
Pa

t = tnom - Ca =
2SEt/D-2tY = P
521.9

t
L/Do
Do/t
4B/3(Do/t) = Pa
A
Thickness, in.
X-Chart

Cylinder Capacities

13.69 102 853.72 0.01
8.5
Plate Data
68.02 3572.5 0.2833 lbs/cu in
Stress Value
Pa
9787.6

Sq In
Author: JLW
Page 13
Total lb's
lb's of
Steel
1012.1
Prod + Steel
1021
Page 3 of 3
Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010

Material
A 106
Company, Line#
ACME Chemical, 24-6-HS-CS
Temp.F Size
650
6
OD
Sch
t nom
6.625 0.432
80
Flange Weight
81
Lbs
Quantity
Total Flange Weight
162.0
Valve Weight
720
Lbs
Quantity
Total Valve Weight
720.0
Insul.
Calcium Silicate
Tk
Other Load
3.00
in.
Wt.
7.13
Wt.
Quantity
Lb/Ft TIW
0
142.6
0.0
TOW
3.313
Outside Radius (in.)
r
SG
2.881
0.01
Inside Radius (in.)
W1
2.381
Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)
Superheated HP Steam
240
1025
Support Spacing (in.)
0.009
Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)
Ss
L
W2
17000
0.000
Material Sress (psi)
0S
ca
Material Catagory CS/Crom. Stl
Center Load (lbs)
Mo1
61476
Mo2
78688
0.143
Corrosion allowance (in.)
Wm 0.2833
lbs/cu in
Load Bending Moment (in.-lbs) (Ss*L)/4)

Max Bending Moment (in.-lbs)
(Mo1+[W1+W2]*Ss*[Ss/8])
Minumum Required thickness (in.)

([R]-[[R^4]-[[R*Mo2*4/[S*Pi]]]^.25)+ca
Pipe hanger load evaluation (ASTM A36 or A575)

Valves
Flanges
Other Wt
Ins. Wt
Total Load
285.2
285.2
Rs 0.50
Rod Sizes (Dia.)
Rn 2
Number of Rods/Pipe Support
ML 1130
Supported Length
Da
Tw
1031
Total Support Load (lbs)
SL
2260
Support Load Max (lbs)
46
Load/Rod
480
in.
% Stressed
Piping Support Sufficient
NOTES:
Project :
24HS-PIPING
Company, Line# ACME Chemical, 24-6-HS-CS
Page 14

Material
A 106
Company, Line#
Temp.F Size
650
3
Sch
OD
t nom
80
3.5
0.300
Flange Weight
23
Lbs
Quantity
Total Flange Weight
46.0
Valve Weight
170
Lbs
Quantity
Total Valve Weight
170.0
Insul.
Calcium Silicate
Tk
Other Load
2.00
in.
Wt.
2.84
Wt.
Quantity
Lb/Ft TIW
56.8
0.0
TOW
1.750
r
SG
1.450
0.01
Inside Radius (in.)
W1
0.854
240
273
0.002
Ss
L
W2
0S
ca

Center Load (lbs)
17000
0.000
Mo1
16368
Mo2
22537
0.158
Wm 0.2833
lbs/cu in

(Mo1+[W1+W2]*Ss*[Ss/8])

([R]-[[R^4]-[[R*Mo2*4/[S*Pi]]]^.25)+ca

Valves
Flanges
Other Wt
Ins. Wt
Total Load
113.6
329.6
Rs 0.375
Rn 2
ML 610
Rod Sizes (Dia.)

Tw
597
SL
1220
49
Load/Rod
Supported Length
Da
480
in.

% Stressed
NOTES:
Project :
24HS-PIPING
Page 15

Material
A 106
Company, Line#
Temp.F Size
650
10
Flange Weight
190
Lbs
Quantity
Valve Weight
1880
Lbs
Quantity
Insul.
Calcium Silicate
Tk
Other Load
3.00
in.
Wt.
OD
Sch
t nom
10.75 0.365
40
Total Flange Weight
380.0
Total Valve Weight 1880.0

10.5
Wt.
Quantity
Lb/Ft TIW
0
210.0
0.0
TOW
5.375
r
SG
5.010
0.01
Inside Radius (in.)
W1
3.374
240
2470
0.028
Ss
L
W2
Mo1
148200
17000
0.000
Mo2
172695
0.116
0S
ca
Center Load (lbs)
Wm 0.2833
lbs/cu in

(Mo1+[W1+W2]*Ss*[Ss/8])

([R]-[[R^4]-[[R*Mo2*4/[S*Pi]]]^.25)+ca

Valves
Flanges
Other Wt
Ins. Wt
Total Load
420
420
Rs 0.50
Rod Sizes (Dia.)
Rn 2
ML 1130
Supported Length
Da
Tw
1481
SL
2260
66
Load/Rod
480
in.
% Stressed
NOTES:
Project :
24HS-PIPING
Page 16
APPENDIX B
Thickness Measurement Record
Page 17
API-570 PIPING EVALUATION

Piping Inspection Data
Report No
N-24HS-PIPING
Client
ACME Chem.
Inspector
Circuit
Date
Jeff Walling
Circuit 36
7/12/2010
Component Thickness Measurements (in inches)

Components with Vert. Axis: tml-1 N., tml-2 E., tml-3 S., tml-4 W. (Drawing N.)
Components with Horz. Axis: tml-1 Top, tml-2 Side, tml-3 Bttm., tml-4 Side (Clock Wise)
CML #
Line No.
Size
Comp. Disc
001
24-HS-6-CS-B2-1
Elbow 45
0.454
0.454
002
24-HS-6-CS-B3-1
Elbow 90
0.304
0.304
003
24-HS-6-CS-B3-1
Elbow 90
0.281
0.281
004
24-HS-6-CS-B3-1
Elbow 90
0.299
0.299
005
24-HS-6-CS-B4-2
Elbow 90
0.438
0.438
006
24-HS-6-CS-B4-2
Elbow 90
0.682
0.682
007
24-HS-6-CS-B4-2
Straight Pipe
0.428
008
24-HS-6-CS-B4-2
Elbow 90
0.301
0.301
009
24-HS-6-CS-MSH-3
Straight Pipe
0.426
0.426
010
24-HS-10-CS-MSH-3
10
Elbow 90
0.416
0.416
011
24-HS-10-CS-MSH-3
10
Elbow 90
0.403
0.403
012
24-HS-10-CS-MSH-3
10
Elbow 90
0.357
0.357
013
24-HS-10-CS-MSH-3
10
Tee Fitting
0.377
0.377
014
24-HS-10-CS-MSH-3
10
Straight Pipe
0.321 0.338 0.357
0.321
015
24-HS-10-CS-MSH-4
10
Straight Pipe
016
24-HS-10-CS-MSH-4
10
Straight Pipe
0.367
0.367
017
24-HS-10-CS-MSH-4
10
Straight Pipe
0.368
0.368
018
24-HS-10-CS-MSH-4
10
Straight Pipe
0.462
0.462
019
24-HS-10-CS-MSH-4
10
Straight Pipe
0.261
0.261
020
24-HS-6-CS-BP-4
Elbow 90
0.382
0.382
021
24-HS-10-CS-MSH-4
10
Straight Pipe
0.260
0.260
Report No.: 24HS-PIPING
Page 18
tml-1 tml-2 tml-3 tml-4
0.462
0.413 0.375 0.400
t act
0.428
0.375
CML #
Line No.
Size
Comp. Disc
022
24-HS-6-CS-MSH-4
Elbow 90
0.424
0.424
023
24-HS-6-CS-MSH-4
Straight Pipe
0.424 0.431 0.437
0.424
024
24-HS-6-CS-MSH-4
Straight Pipe
0.450 0.445 0.404
0.404
025
24-HS-6-CS-BP-4
Elbow 90
0.377
0.377
026
24-HS-6-CS-MSH-4
Straight Pipe
027
24-HS-6-CS-MSH-4
Straight Pipe
0.432 0.431
028
24-HS-6-CS-MSH-4
Elbow 90
0.282
0.282
029
24-HS-6-CS-MSH-4
Elbow 90
0.396
0.396
030
24-HS-3-CS-C3-4
Elbow 90
0.223
0.223
031
24-HS-3-CS-C3-4
Straight Pipe
0.276
0.276
032
24-HS-3-CS-C2-4
Elbow 90
0.239
0.239
033
24-HS-3-CS-C2-4
Elbow 90
0.241 0.235 0.259
0.235
034
24-HS-3-CS-C2-4
Straight Pipe
0.211
0.211
035
24-HS-3-CS-C1-4
Elbow 90
0.240
0.240
036
24-HS-3-CS-C1-4
Straight Pipe
0.250
037
24-HS-6-CS-B5-2
Elbow 90
0.495
038
24-HS-6-CS-B5-2
Straight Pipe
039
24-HS-6-CS-B5-2
Elbow 90
0.540
0.540
040
24-HS-6-CS-MSH-4
Tee Fitting
0.591
0.591
041
24-HS-10-CS-MSH-3
10
Tee Fitting
0.352
0.352
Report No.: 24HS-PIPING
Page 19
tml-1 tml-2 tml-3 tml-4
t act
0.418 0.403
0.403
0.413
0.413
0.268 0.255
0.250
0.495
0.504 0.478
0.478
APPENDIX C
API 570 Inspection Checklist
Page 20
Report No.:
24HS-PIPING
ITEM
Company:
ACCEPTABLE
Iso No:
ACME Chemical
UNACCEPTABLE
Jeff Walling
Inspector:
API-570 PIPING INSPECTION CHECKLIST
Line No:
N/A
24-HS-3
24-HS-10-CS-MSH
Cert No.:
Date:
COMMENTS
LEAKS?
flange leak on manifold iso valve
Process
Steam tracing
Existing clamps
MISALIGNMENT?
Pipe misalignment/restriction
Expansion joint alignment
VIBRATIONS?
Excessive overhung weight
Supports
Thin, small-bore alloy piping
Threaded connections
SUPPORTS?
where visible, no sig. distortion or corrosion
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Slide plates/rollers
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Soil-to-air interface
Insulation interface
Biological growth
INSULATION?
Damage/penetrations
minor spots
Missing jacketing/insulation
minor spots
Sealing deterioration
Bulging
Banding broken/missing
Notes:
Insulation 3" CalSil
Page 1 of 4
Page 21
0341
7/12/2010
Report No.:
24HS-PIPING
Company:
ITEM
ACCEPTABLE
Iso No:
ACME Chemical
UNACCEPTABLE
Jeff Walling
Inspector:
Line No:
N/A
24-HS-4
24-HS-10-CS-MSH
Cert No.:
Date:
COMMENTS
LEAKS?
Process
Steam tracing
Existing clamps
MISALIGNMENT?
VIBRATIONS?
Supports
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Biological growth
INSULATION?
Damage/penetrations
minor spots
minor spots
Bulging
Notes:
Page 2 of 4
Page 22
0341
7/12/2010
Report No.:
24HS-PIPING
Company:
ITEM
ACCEPTABLE
Iso No:
ACME Chemical
UNACCEPTABLE
Jeff Walling
Inspector:
Line No:
N/A
24-HS-1
24-HS-6-CS-B2/3
Cert No.:
Date:
COMMENTS
LEAKS?
Process
Steam tracing
Existing clamps
MISALIGNMENT?
VIBRATIONS?
Supports
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Biological growth
INSULATION?
Damage/penetrations
minor spots
minor spots
Bulging
Notes:
Page 3 of 4
Page 23
0341
7/12/2010
Report No.:
24HS-PIPING
Company:
ITEM
ACCEPTABLE
Iso No:
ACME Chemical
UNACCEPTABLE
Jeff Walling
Inspector:
Line No:
N/A
24-HS-2
24-HS-6-CS-B4/5
Cert No.:
Date:
COMMENTS
LEAKS?
valve stem leak on #4 boiler iso valve
Process
Steam tracing
Existing clamps
MISALIGNMENT?
VIBRATIONS?
Supports
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Biological growth
INSULATION?
Damage/penetrations
minor spots
minor spots
Bulging
Notes:
Page 4 of 4
Page 24
0341
7/12/2010
APPENDIX D
Inspection Drawings
Report No.: NASA-24HS-PIPING
Page 25
Page 26
Page 27
Page 28
Page 29
APPENDIX E
Inspection Photographs
Page 30
ACME CHEMICAL BLDG 24 HIGH PRESSURE STEAM (HS)

REPORT N-24HS-PIPING
INSPECTION PHOTOGRAPHS
Boiler #4 line 24-HS-6-CS-B4-1 (typical to all boilers)
Missing insulation HS Main
Page 31

Boiler #2 line 24-HS-6-CS-B2-1 (missing insulation)
Page 32

Distribution Manifold 24-HS-10-CS-MSH-3 (flange joint steam leak)
Page 33

By pass line 24-HS-6-CS-BP-4
Main Steam Header 24-HS-10-CS-MSH-4
Page 34

Main Steam Header expansion loop 24-HS-6-CS-MSH-4
HS to Chiller #2, line - 24-HS-6-CS-C2-4
Page 35
APPENDIX F
NDE Reports
1) UT Calabration Report
2) NDE Technician Certification
3) API-570 Inspector Certification
Page 36
ULTRASONIC EXAMINATION REPORT

CLIENT: ACME Chemicals
CLIENT PO #: 10002-001
REPORT NO.: N-24HS-PIPING
EIT JOB #: 10032
EQUIP ID: HS Piping Bld 24
SERVICE: High Pressure Steam
JOB DESCR.: 330 ft high pressure steam piping thickness readings.
EXAM DATE: 07/16/2010
PROCEDURE #: EIT-UTT-01
SPECIFICATION: API-570
MATERIAL: CS
TEST PARAMETERS
Unit: Panameterics DL37+
Long Frq
SW Frq:
mHZ
mHZ
SW Frq:
mHZ
SW Frq:
mHZ
Size:
Size:
Size:
Size:
UT UNIT
S/N: 5904
Cal Date: 11/11/09
PROBE SPECIFICATIONS
.375
Type: D790
Type:
Type:
Type:
S/N 905216
S/N
S/N
S/N
COUPLANT
Surface Cond: Coated
MFG: Ultra Grade Gel-40
CALIBRATION STANDARD
Type: Raycheck 6 Step Block
S/N: 00-7235
Calibration Reference Level (db)
0: 51
45:
60:
Other:
0:
45:
60:
70:
Start Time: 0800
End Time:
End Time: 1200
Start Time:
Results/Comments: Reference API-570 Report
UT Level II Technician:
Jeff Walling
Page 37
70:
Jeffrey Walling
EAGLE I. TECHNOLOGIES
NAME:
NDT CERTIFICATION / QUALIFICATION RECORD
Employee ID Number:
NDT CERTIFICATIONS
EXAM SCORES
3965
METHOD
LEVEL
DATE
EXAMINER
GENERAL
SPECIFIC
PRACTICAL
COMPOSITE
EXPIRATION
DATE
RESTRICTIONS
UTT
PT
MT
MFE
II
II
II
II
4/9/2010
9/3/2010
9/3/2010
1/21/2011
Joe Monroe
Wayne Bailey
Wayne Bailey
Brian Rotto
86%
93%
93%
90%
100%
95%
95%
85%
95%
91%
85%
89%
94%
93%
91%
88%
4/9/2015
9/3/2015
9/3/2015
1/21/2016
thickness only
None
None
None
PREVIOUS EMPLOYER NDT CERTIFICATIONS

COMPANY NAME/ADDRESS
FROM
TO
NDT METHODS & HIGHEST LEVEL ATTAINED
CAPE
Westech Inspection
BP/GIANT
MATIS
6/2009
1/19/2004
9/1/1998
9/16/1995
9/2013
11/20/2009
4/15/2003
9/1/1998
Level II UTT/MT/PT/MFE
Level II UT thickness limited
Level II UTT/MT/PT/LT
Level II UTT/MT/PT
EYE EXAMINATION
DATE
TYPE
10/22/2012
Far
10/22/2012
Near
10/22/2012 Color Contrast
TESTED BY
Amer. Best
Amer. Best
Amer. Best
EDUCATION AND TRAINING

PASS / FAIL
Pass
Pass
Pass
refer to employee eye exam cert (CAPE-FRM-101)
OTHER NOTABLE CERTIFICATIONS OR

QUALIFICATIONS
CERT
EXP DATE
CERT
EXP DATE
API 653
4/30/2014
PD DEP
1/10/2016
API 510
API 570
STI
6/30/2014
6/30/2014
9/18/2017
NB Comm.
VA-B&PV Com
MET.AS
2014
2013
2012
Jeff Walling
NDE PROGRAM MANAGER
ASNT
CERT No.
SIGNATURE
10/22/2012
DATE
EIT Certification Record Form: CAPE-FRM-102
INSTRUCTOR
ORG
DATE
LENGTH
SUBJECT
David Spooner
David Spooner
Joe Monroe
MATIS
12/16/1997
12/16/1997
4/9/2010
12 hours
12 hours
24 hours
Level II UTT
Level II PT
Level II UTT
8/25/2010
8/27/2010
1/21/2011
20 hours
12 hours
8 hours
Level II MT
Level II PT
Level II MFE
Stan Meyer
Stan Meyer
Brian Rotto
MATIS
Eastern NDT
WCFS
WCFS
CAPE
TRAINEE / LEVEL I NDT HOURS (IF APPLICABLE)

METHOD
EMPLOYER
HOURS
TOTAL
DATE
This NDT Qualification record is in accordance with EIT-WP-01 and SNT-TC-1A (2006). All historical
information supplied for this document is true and accurate to the best of my knowledge.
Page 38
Page 39
APPENDIX G
P&ID's
Page 40

ACME Chemicals: High Pressure Steam (HS) Piping

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ACME Chemicals

Report No.: N-24HS-PIPING

High Pressure Steam (HS) Piping

Mechancial Integrity Calculations

Thickness Measurement Record

API 570 Inspection Checklist

Report No.: N-24HS-PIPING

1.0 EXECUTIVE SUMMARY

Next UT inspection is due by:

Governing component limiting life:

Report No.: N-24HS-PIPING

2.0 PIPING DATA

High Pressure Steam (HS) Piping

Build Date: (yr)

10", 6" & 3" Mains

Sup. Span (ft.):

Design Temp.: (F)

Oper. Press.: (psi)

Oper. Temp.: (F)

Calcium Silicate (12.5lb ^3ft)

Insulation Thk.: (in) 3

Report No.: N-24HS-PIPING

3.0 INSPECTION RESULTS

Report No.: N-24HS-PIPING

4.8 Next Inspection:

4.8.3 Next UT inspection is due by

4.8.4 Governing component limiting life

Report No.: N-24HS-PIPING

5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS

5.1 Results Summary:

Report No.: N-24HS-PIPING

Report No.: N-24HS-PIPING

API-570 PIPING EVALUATION

Minimum Thickness Determinations:

b) Large size pipe components or components subject to high

t prev t act t min

Pipe Component Remaining Life Calculations:

t prev t act t min

PIPE COMPONENT PRESSURE CALCULATIONS

ASME B31.1 104.1

Internal Pressure Minimum Thickness Calcs

Outside Diameter, in.

17000 Stress, psi

Minimum Thickness, in.

External Pressure Minimum Thickness Calculations

Effective Length, in.

Outside Diameter, in.

Factor from Figure G

External Pressure, psi

Minimum Thickness, in.

Internal Pressure Calculations

0.101 Thickness, in.

External Pressure Calculations

External Pressure, psi

lb's of Prod lb's of

Project No.: 24HS-PIPING

2.881 Shell Radius, in.

Factor from Figure G

Variables for Capacities

Internal Pressure, psi

Line No. 24-3-HS-CS-C1

Internal Pressure Minimum Thickness Calcs

Design Pressure, psi

Pipe Weight (lbs/in.) ([R^2]-[r^2]PiWm)

Fluid Weight (lbs/in.) (Pir^2SG*0.03613)

Pipe Weight (lbs/in.) ([R^2]-[r^2]PiWm)

Fluid Weight (lbs/in.) (Pir^2SG*0.03613)