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Piping & Hanger

Korea Electric Power Research Institute


Power Generation Research Laboratory

Jung-Seob Hyun
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Stress Analysis

Fatigue Test Diagnosis of Piping & Support

Data Base System

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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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Session 1 : Introduction of Piping System

Contents
1. Introduction 2. Damage Examples of Pipe and Supports

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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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What is the piping supports?


- Hanger, Restraint and Snubber are types of piping support - If piping support is rigid, it creates excess stress at the piping welding area

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2. Damage examples of piping & support


Damage examples of pipe (1)
Swelling of steam pipe
- in the end of creep life - surface hair crack, swelling - swelling area Dia. : 209mm -> 230mm Length : 550mm - Since1993, We have managed life consumption -> prevention of pipe rupture

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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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Damage examples of pipe (2)


Pipe Rupture
- Rupture in weld area at elbowed pipe - It caused by excess stress concentration

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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Damage examples of pipe hanger (1)


Error of cold position setting
- It needs adjustment of hanger load and cold position when hanger is installed during the construction - Wrong adjustment induced rigid hanger motion - Adjust correct cold position by using the hanger Turnbuckle

Crack of pipe Lug area


- Crack of pipe lug at rigid hanger - rigid hanger is installed at 1/3 position of vertical pipe line - stress concentration in lug area during the frequent startstart-up, shutshut-down

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Damage examples of pipe hanger (2)


high vibration of turbine casing by support deviation
- Abnormal displacement due to support deviation - Deviation and excess vibration of turbine casing body - It need to balance pipe support by adjusting pipe hanger

Hanger rod rupture


- Rod rupture is induced by abnormal displacement and high vibration - Crack due to stress concentration by hanger rod rupture

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Cracked shape of elbowed pipe

Damage of Pipe support

Rapid increase of technical

su pp or ts ys te m

Life extension by early detection and preventive maintenance of pipe line

Increase of abnormal displacement

supports for piping and support

of pipe line

of pi pe

&
Frequent start-up, shut-down Abnormal vibration of pipe line

and severe operating condition


Increase of old power plants

by damaged supports

M ai nt en an ce

Replacement of pipe line by cracks in the weld area

above 20 years (about 70%)

Pipe Swelling in the end of life before the pipe rupture

Importance of maintenance for piping and supports


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KEPRI - LAST Damage mechanism of pipe Creep

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

Thermal fatigue or creep-fatigue

Independent thermal fatigue or dependent creep-fatigue in frequently start-up, shut-down

material degradation

Creep-fatigue voids, embrittlement, hardening, softening, corrosion by material degradation


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Damage mechanism of pipe support (hanger)


Stick of rotating arm

It caused by oxide scale because hanger installed at outside

Scale over of Travel indicator

It caused by sticking of rotating arm or internal spring Design error of hanger load, displacement, thermal movement

Rupture of hanger spring or Rod

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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Session 2 : Design of Piping System

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

1.2 Design Considerations : Loadings


1) 2) 3) 4) 5) 6) Internal & external Pressure : Design pressure Hammering or Jet Force due to sudden pressure change Deadweight of fluids, pipe, insulation Wind, snowfall, vibration and seismic loads Reaction forces of supports Thermal expansion Loads

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1.3 Design Considerations : Operating Conditions


1) Design condition - Deadweight(fluids, insulation, valve etc.) - design pressure - seismic load 2) Normal operation - Deadweight - Internal pressure - thermal expansion load 3) abnormal operation - Deadweight - Internal pressure - thermal expansion load - Dynamic loads

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1.4 Design Limits : Stresses


1) Primary stress(by the pressure) Normal, shear or bending stresses generated by the imposed loading which are necessary to satisfy the laws of equibrium of internal and external forces and moments - Dead load by the weight - longitudinal and circumferential stresses due to internal pressure 2) Secondary stress(by the thermal) Varying from positive to negative across the pipe wall thickness because of differential radial deflection of the pipe wall - circumferential bending stress in a curved pipe 3) Localized stress Peak stress due to stress concentration - stress by local discontinuity + primary + secondary - a source of direct failure

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1.5 Design Limits : Allowable Stress


1) 62.5% stress of yield stress at operating temperature 2) 0.01% creep stresss during 1,000hr at operating temperature 3) Equation by the ASME B31.1 Power Piping Code

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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2. Piping Codes and Standards


The objective of Code rules and Standards : achieve minimum requirements for safe construction. <List of primary standard and specifications> 1) American National Standard Institute(ANSI) - ANSI B 16.5 : Spec. of piping fitting 2) Manufacturers Standardization Society of the Valve & Fitting Industry(MSS) - MSS SP-58 : Material, design, manufacturers of pipe hangers and supports - MSS SP-69 : Selection and application of pipe hangers and supports - MSS SP-89 : Fabrication and installation practices of pipe hangers and supports 3) American Society of Mechanical Engineers(ASME) - B31.1 : Power piping - B31.2 : Fuel gas piping - B31.3 : Chemical plant & petroleum refinery piping - B31.4 : Liquid petroleum transportation piping 4) American Society for Testing and Material (ASTM) - Spec. of Piping material 5) American Welding Society(AWS) 6) American Petroleum Institute(API)

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3. Basic Equations of Piping Stress Analysis


ASME B31.1 Analysis of piping components 1) Stress due to sustained loads

2) Stress due to occasional loads


k = 1.15 ( < 10% of 24hr operating period) = 1.2 (<1% of 24hr operating period)

3) Thermal expansion loads

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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4. Stress Evaluation of Piping System


Piping Analysis Program(Pipepak, ANSYS etc.) 1) Thermal expansion loads
A. Thermal expansion

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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KEPRI - LAST 2) Calculate Thermal Stress


ASME B31.1 Power Piping Code Piping modelling - Isometric

Drawing
Input loads - sustained loads,

occasional, thermal loads


Input boundary condition

Boiler, Turbine, supports


Analysis Dead Weight

- Compare design load


Analysis displacement/stress

- Compare design data


extra displacement Simulation Bad supports

- Cause analysis
Optimal repair

- Pipe & supports

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Session 3 : Piping Support System

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.

high resistance against rapid displacement caused by dynamic loads

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2. Structure of piping supports 2.1 Constant spring hanger


Horizontal movement : < 4 degree ( swing ) Support constant load Variable support load : 10% Read vertical movement Indicated by Travel Index Plate Vertical movement : > 50mm Load change rate : Theoretically 0, but really < 6%

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Lever Type

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Horizontal Type (Old Type) Installation Hole of Locking Rod Vertical Type (New Type)

Horizontal Type (New Type)

Locking Device

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Locking before hydro test

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How to calculate pipe displacement ?


A. Index plate divided by 10 space B. Design maximum Travel 140mm, Cold movement : 0, Hot movement : 7 C. Pipe vertical movement : 98mm - 1 space : 140/10=14mm - total 7 space : 147=98mm

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Sliding Type

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How to calculate pipe displacement ?


A. Directly Calculate Index from plate B. Insert locking device before hydro test

Locking Device

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KEPRI - LAST Typical damage of constant spring hanger

Locking state during operation

Separation Indicator from travel

Scale over Upper/Lower Limit

Locking state during operation


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Interfere with pipe and hanger

Internal corrosion or rust


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2.2 Variable spring hanger


Small size, Small weight Sometimes used as Rigid hanger by lock pin Load travel is linear (indicated by Index Plate) Load change rate : < 25% Vertical movement : < 50mm

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Old Type (locking by Pin Inserting) New Type (Locking by Nut)

Locking Device

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How to calculate pipe displacement ?


A. Directly Calculate Index from plate - Read the travel and load values in the name plate at cold and hot position - Read the lower position of spring plate B. Insert locking device before hydro test

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KEPRI - LAST Typical damage of variable spring hanger

Internal corrosion and rust

Locking state It is not locking state in this picture

Scale over Upper/Lower Limit

Deviation of installed position


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Indicator of variable spring hanger


- Read the travel and load values in the name plate at cold and hot position - Read the lower position of spring plate

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2.3 Other hangers


Unbalancing loads of rigid hanger rod * In the case of rigid hanger, it must inspect installation load Malfunction of anchor and guide Rupture damage of rod Damage of snubber

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Load Variability of Spring Hanger V = (Wh-Wc) / Wh (%)

Cold Load

Load Variability

Hot Load

Displacement

ex)
Pipe displacement

Variable spring hanger, k =10kg/mm, = 10mm, Wc = 400kg Wh, V = ?

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3. Inspection of piping supports 3.1 Introduction


1) Preliminary data Isometric Drawing - position of Hangers

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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

After the O/H (Hot state) : in case of adjusting hanger travel


* Indicator position must be recorded before and after overhaul

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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3.2 Analysis of inspection results


(1) Recording of indicator travel Recording all items - Inspection date, power output, pipe line name, hanger number, hanger specifications, design values Recording cold and hot position of travel without omission on the basis isometric drawing Use the Excel program for graphing data as possible * Actual piping displacement is represented with graphs using Excel program and is compared to that of design displacement <example>

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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

Design displacement Actual displacement

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KEPRI - LAST Design and actual displacement (abnormal state)


250 200 150 100 50 0 -50 -100 511C001 511C003 511C006 511C007 521C001 521C003 521C005 521C007 002C001 002C004 002C005 002C008 Des ign dis placement Actual dis placement

180 160 140 120 100 80 60 40 20 0 -20 -40

Design displacement Actual displacement

C001 C002 C003 C004 C005 C006 C007 C008 C009 C010 C011 C012 C013 C014 C015 C016 C017 C018 C019 C020

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4. Adjustment of piping hanger


Preliminary action
- Preparation of Scaffolds and Chain block - Cleaning bolts, nuts and hanger turnbuckle area

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Recording travel indicator


Hot state Cold state Discussion of adjust method

Adjustment of hanger travel


Adjust hanger travel by using the hanger turnbuckle adjust hanger travel : rotate turnbuckle - From top point(0) to bottom point(10) : rotate turnbuckle in clockwise - From bottom point to top point : rotate turnbuckle in counterclockwise Adjust hanger load by rotating nuts for using the load change adjust hanger load : rotate nuts - Increase hanger load : rotate nuts in clockwise - decrease hanger load : rotate nuts in clockwise Observation of adjacent hangers - From high-elevation to low-elevation Recording travel indicator at final cold position

Recording travel indicator at hot state


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5. Replacement of piping hanger

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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

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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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6. Damage Examples of Hanger 6.1 Stick of rotating arm

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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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6.2 Spring & Rod Rupture of Constant and Spring hanger


- Spring rupture : Outside installed hanger, brittle fracture induced by surface corrosion, stress corrosion - Rod rupture : perfectly stick inside hanger. when it was over-loaded, neck area of rod is fractured

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6.3 Cracks of Support Lug


- P.T Check of support lug for not moving spring hanger - crack of weld area

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Damage examples of piping & hanger system


A. ULSAN Power Plant #4 Hot Reheat Pipe B. SAMCHUNPO Power Plant #4 Main Pipe Line C. Dong-hae Power Plant #1 Main Steam Line D. Ho-nam Power Plant #2 HP Bypass Line

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A. Damage of Hot Reheat Pipe for ULSAN Power Plant #4


1) History
- After construction, hot reheat pipe is producing excess displacement in vertical pipe line over 20 years - From this phenomenon, Pipe is contacted with conctrete floor - Crack is generated by over stress in welded area of elbow

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2) Displacement and thermal stress analysis

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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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4) Repair of cracked area


- Welding and heat treatment of cracked area - Movement up(70mm) of Vertical line by using the hydraulic device and rigid hanger(U12) - U14, U16, U17, U18 Hanger balancing at cold state - Digging 100mm concrete floor for stress relaxation

5) Replacement of pipe
- Calculate plastic deformation - Test of tension, indentation, hardness - Replacement of 35m pipe line

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B. Damage of Main Pipe Line for SAMCHUNPO Power Plant #4


1) History
When HIP shell center line GIB key is released, HIP shell movement of TBN casing excess limit of movement Movement of Front Standard & Sole Plate high vibration of TBN

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2) Thermal expansion of main pipe line


Displacement of hot reheat line and main steam line is unbalancing due to sticked hanger Shell movement of casing excess limit Move Front Standard & Sole Plate

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3) Displacement and thermal stress analysis <Hot Reheat Line>

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Cut and Insert New Pipe

System2 Hanger 10mm

System3 Hanger 66mm

Deviation 56mm

System2 Hanger 62mm

System3 Hanger 77mm

Deviation 15mm

Design Deviation 20.8mm

Rehabiliation of Piping design displacement


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C. Damage of Main Pipe Line for Dong-hae Power Plant #1

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51E Hanger (13 Floor)

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D. Damage of Pipe Line for Ho-nam Power Plant #2


- Diagnosis of main pipe hanger (Main Steam, Hot Reheat, Cold Reheat) - Actual displacement of Main Steam, Hot Reheat Line Hanger is agree with design displacement

90 80 70

160

Design Displacement Actual Displacement

140 120

Design Displacement Actual Displacement

Total Displacement (mm)

60 50 40 30 20 10 0 0 2 4 6 8 10 12 14 16 18 20 22

Total Displacement (mm)

100 80 60 40 20 0 -20 0 5 10 15 20 25

Main Steam Line Hanger No.

Hot Reheat Line Hanger No.

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KEPRI - LAST - Abnormal displacement of HP Bypass Line


Total Displacement (mm)
70 60 50 40 30 20 10 0 0 2 4 6 8 10 12

Design Displacement Actual Displacement

HP Bypass Line Hanger No.

2001. 4
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Session 4 : On-line Monitoring System of Piping

Contents
1. Introduction 2. Development of Measurement Device for 3-D Piping Displacement 3. On-line Monitoring Technology

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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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LVDT type piping displacement measurement


The distance and angles at one point in the spherical coordinate can be measured and transformed into rectangular coordinate - Two encoder measures 2 angles and - One LVDT measures the distance r

Z Moving point A (Universal joint) angles , (Encoder 2) Y Distance r (LVDT)

X
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Multi-link type piping displacement measurement


1. To minimize any possible error depending on an installation location. 2. To reduce the weight of instruction and cut down cost - Link l1 and l2 are constant. 1, 2 and 3 is absolute angle that is measured from encoder.

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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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Z (mm) 300.39 400.23 300.28 400.15

Error range (%) +0.13 +0.05 +0.09 +0.03

1 2 3 4

Two types of equipment have precise measurement


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The demonstration in the field(LVDT type)

Actual displacement at installed location under full load X : 22mm Y : -37 mm Z : 26mm
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The results of demonstration

Sudden Drop 5times

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3. On-line Monitoring Technology

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The field application : LVDT type, B fossil power plant

On-line Monitoring

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Monitoring program

Monitor part
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Control part
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KEPRI - LAST The measured results(LVDT type, B fossil power plant)


200 Full Power 150 Preheat of Turbine 100 Displacement (mm) .. Hanger Unlocking 50 Preparation for Operation Boiler Start Turbine Start
MS2-X MS2-Y MS2-Z MS2-L MS12-X MS12-Y MS12-Z MS12-L MS23-X MS23-Y MS23-Z MS23-L

-50

-100

-150 0 0.5 1 1.5 2 2.5 Period (day) 3 3.5 4 4.5

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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)

piping displacement measurement of T fossil power plant (Turbine inlet)


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KEPRI - LAST The measured results (8th floor, T fossil power plant)

piping displacement measurement of T fossil power plant (Y-piece)


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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

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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

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