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Jung-Seob Hyun
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Stress Analysis
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Contents
1. Session 1 : Introduction of Piping System (0.5hr) Introduction Damage Examples of Pipe and Supports 2. Session 2 : Design of Piping System (1.0hr) Introduction Piping Codes and standards Basic equations of piping stress analysis Stress evaluation of piping system
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3. Session 3 : Piping Support System (1.0hr) Introduction Support(Hanger) Type & Load System Damage examples of piping & hanger system
4. Session 4 : On-line Monitoring System of Piping (0.5hr) Introduction Development of Measurement Device for 3-D Piping Displacement On-line Monitoring Technology
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Contents
1. Introduction 2. Damage Examples of Pipe and Supports
1. Introduction
What is the piping displacement?
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- Thermal expansion of Piping Line expands toward 3 axis direction - Piping hangers support thermal expansion load and deadweight during operation
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Pipe cracks
- Excess displacement by frequent startstart-up, shutshut-down - Contacted with concrete floor, Longitudinal cracks by compression stress above allowable stress
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Pipe Deviation
- Deviation of main steam and hot reheat line - Damage of hydraulic snubber - It caused by abnormal displacement of sticked hangers
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su pp or ts ys te m
of pipe line
of pi pe
&
Frequent start-up, shut-down Abnormal vibration of pipe line
by damaged supports
M ai nt en an ce
Circumferential direction : - thermal expansion of pipe - Type crack by creep cavity, - Bending Stress Longitudinal direction : - internal pressure of pipe - residual stress in weld area - swelling in the end of creep damage
material degradation
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It caused by sticking of rotating arm or internal spring Design error of hanger load, displacement, thermal movement
It caused by surface corrosion, stress corrosion of hanger spring Rod rupture by rigid motion of sticked hanger in over-loaded pipe line
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Contents
1. Concept of Piping System 2. Piping Codes and standards 3. Basic equations of piping stress analysis 4. Stress evaluation of piping system
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1. Piping Design
1.1 Pipe properties
1) 2) 3) 4) 5) 6) 7) Pipe O.D(I.D) : tolerance Material : Carbon Steel, Alloy steel(A335-P11,P12,P22,P91), Stainless Steel Pipe Wall Thickness : Nominal, Average, Minimum, Maximum Fluid Contents : Steam, Water, Oil, Gas Insulation : Rock wool, Pearlite, Calcium Silicate Modulus of Elasticity : Material, Temp Thermal Expansion Coefficient : Material, Temp
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SA = 1.25 Sc + 0.25 Sh -> 1.25 f (Sc + Sh) : include safety factor f -> 1.25 (Sc + Sh) : generally consider safety factor is 1
where, Sc : allowable stress of material at ambient temeprature Sh : allowable stress of material at operating temperature
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P : Internal pressure, Do : Outer diameter, tn : Wall thickness, i = stress concentration factor MA : Moment of sustained loads, MB : Moment of occasional loads, MC : Moment of thermal expansion loads, f : safety factor, Z : Section modulus of piping SL : stress summation by sustained loads
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where,
: Thermal expansion movement : Thermal expansion coefficient L : Piping length T : Metal temperature
B. Flexibility of piping - Check the displacement of piping support(hanger) - Check distance of supports, support type, pipe length Computer program Optimal flexibility C. Thermal stress analysis - Requirement stress : 65 - 75% of allowable thermal stress SA - Apply modelling, boundary condition, thermal loads - Calculate thermal stress by using the piping analysis program
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Drawing
Input loads - sustained loads,
- Cause analysis
Optimal repair
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Contents
1. Support (Hanger) Type 2. Structure of Piping Supports 3. Inspection of Piping Supports 4. Adjustment of Piping Hanger 5. Replacement of Piping Hanger 6. Damage examples of Hanger
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1. Support Type
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A. Support deadweight (pipe, insulation, fluids) and thermal expansion loads - Rigid, Constant Spring and Variable Spring Hanger B. Restraint 3D movement by the thermal expansion (Anchor, Guide, Stopper) C. Prevent piping shock by the vibration, hammering occasional loads(Snubber)
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Type Name Rigid Hanger Hanger or Support Spring Hanger (Variable Hanger) Constant Hanger Anchor Restraint Guide Restraint (Stopper) Spring type Snubber Brace Hydraulic Snubber Mechanical Snubber Shock Absorber
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Functions A device used specifically to sustain a portion of weight of the Piping system plus any superimposed vertical loading.
Installation Vertical movement is 0mm or < 2mm Vertical movement < 50mm Load change rate 25% Vertical movement > 50mm Load change rate 6%(theory) Full fixation Prevent ratation one direction movement Prevent translatory movement
Any device which prevents, resist, or limits the free thermal movement of the piping.
A device primarily intended to resist displacement of the piping due to The action of any forces other than those due to thermal expansion or to gravity.
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Lever Type
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Horizontal Type (Old Type) Installation Hole of Locking Rod Vertical Type (New Type)
Locking Device
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Locking before hydro test
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Sliding Type
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Locking Device
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Old Type (locking by Pin Inserting) New Type (Locking by Nut)
Locking Device
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Cold Load
Load Variability
Hot Load
Displacement
ex)
Pipe displacement
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* Isometric drawing must be referred during inspection for confirming position and installation of piping support
Drawing of Pipe Hanger Recording of operating and inspection in the past 2) Inspection time before the O/H (Hot state) during the O/H (Cold state)
* Hanger is inspected minimum 7 days after the plant is shut down
3) Inspection (1) External appearance Bolting and nuts area (high vibration area) deformation and rupture of components Locking state interfere with pipe
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KEPRI - LAST (2) Analysis of design and actual displacement for hanger travel Design and actual displacement (normal state)
250 200 150 100 50 0 C001 C002 C003 C004 C005 C006 C007 C008 C009 C010 Design displacement Actual displacement
160 140 120 100 80 60 40 20 0 511- 511- 511- 512- 514- 516- 521- 521- 521- 522- 524- 526C003 C005 C006 C003 C001 C001 C003 C005 C006 C003 C001 C001
C001 C002 C003 C004 C005 C006 C007 C008 C009 C010 C011 C012 C013 C014 C015 C016 C017 C018 C019 C020
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Working condition - Limit position of travel indicator at cold and hot state (It is impossible to adjust indicator) - Abnormal position (there is no change travel indicator) at cold/hot state - Severe corrosion and rust in internal components - Rod bending - Crack or rupture of hanger rod or internal spring
KEPRI - LAST Preliminary action - Preparation of Scaffolds and Chain block - Cleaning bolts, nuts and hanger turnbuckle area - Locking hanger - Install and load chain block Disconnect of old hanger - Separation of turnbuckle - Grinding of weld parts - Move down of old hanger by using the chain block Installation of new hanger - Confirmation of hanger number with isometric drawing - Move up of new hanger by using the chain block - Connection of new hanger and structural attachments - Connection of new hanger and sling rod (After connected, remove lock pin) - Conjunction of turnbuckle and Adjust travel - Removal of scaffolds and chain block - Recording of cold travel
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- Main damage of hanger - It caused by oxide scale because hanger installed at outside - At operating, indicator is not moved
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3) Over Stress
- When elbow of vertical line is contacted with concrete floor, 234% of allowable stress is generated at cracked area
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5) Replacement of pipe
- Calculate plastic deformation - Test of tension, indentation, hardness - Replacement of 35m pipe line
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Deviation 56mm
Deviation 15mm
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90 80 70
160
140 120
60 50 40 30 20 10 0 0 2 4 6 8 10 12 14 16 18 20 22
100 80 60 40 20 0 -20 0 5 10 15 20 25
2001. 4
Copyright KEPRI-LAST All rights reserved.
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Contents
1. Introduction 2. Development of Measurement Device for 3-D Piping Displacement 3. On-line Monitoring Technology
1. Introduction
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q To introduce on-line displacement monitoring system for high temperature piping q To understand importance of pipe displacement measurement to provide a high degree of confidence in piping system q To introduce an experience that on-line displacement monitoring system applies to steam piping to measure pipe displacement
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Objectives
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q To introduce on-line displacement monitoring system for high temperature piping q To understand importance of pipe displacement measurement to provide a high degree of confidence in piping system q To introduce an experience that on-line displacement monitoring system applies to steam piping to measure pipe displacement
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Vision & Passion for Core Tech. 2. 3D Disp. Measurement Device KEPRI - LAST
X
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Laboratory test
True value Test No. X Y Z X (mm) (mm) (mm) (mm) 300 400 250 200 300 400 350 300 300 400 300 400 300.12 400.09 249.87 199.82 Error range (%) +0.04 +0.02 -0.05 -0.09 Measured value Y (mm) 300.40 400.22 350.16 300.44 Error range (%) +0.13 +0.05 +0.04 +0.15
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1 2 3 4
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Actual displacement at installed location under full load X : 22mm Y : -37 mm Z : 26mm
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On-line Monitoring
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Monitoring program
Monitor part
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Control part
The Total Solution for Plant Life
-50
-100
KEPRI - LAST The field application : Multi-link type, T fossil power plant
Monitor part
Control part
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KEPRI - LAST The measured results (2th floor, T fossil power plant)
KEPRI - LAST The measured results (8th floor, T fossil power plant)
KEPRI - LAST Re-adjustment of 8th floor, T fossile power plant Recover steam pipe displacement by re-adjustment of hanger
Before
Design Compensation Measurement
After
Design Compensation Measurement
Conclusion
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(1) The study developed an LDVT type and a Multi-link type measurement device to measure 3-dimensional thermal expansion displacement of the pipe and developed a program that can measure and monitor obtained data from the measurement devices on-line. (2) Three-dimensional data that were gained from the two-type displacement measurement devices turned out to be similar to the ones in normal operations from each direction, proving the credibility of the displacement monitoring system. In the case of P fossil plant, piping displacement out of the designed displacement range was found, indicating that an adjustment of hanger that is supporting the piping was necessary for better management of fossil plant durability. (3) The developed system is expected to greatly contribute to stable operations of main piping if it is applied to various domestic power plants and further applied to high-temperature and high-pressure piping such as in the heat absorption and in the oil-chemistry industry.
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Thank you!
Korea Electric Power Research Institute (KEPRI) Jung-Seob Hyun