Runtime Extension and Optimising.

Inspection of Pressure Equipment.

Dipl.-Phys. Herbert Gries
Contents.

 Legal framework conditions

Periodic inspections,
inspection intervals,
extension of the inspection interval
 Determination of test intervals
Principles, methods
 Extension of test intervals
Official exemption, procedure, methods,
Case study
 Substitute tests, additional tests
Non-destructive materials testing,
industrial instrumentalisation

2 H. Gries, 2013/07
Legal Framework Conditions.
German Ordinance on Industrial Safety and Health - BetrSichV.

Periodic inspection of pressure equipment -

Type and scope
(cf. §15 BetrSichV, Technical Rule TRBS 1201-2)

 External inspection:
Inspection during ongoing operation;
inspection of the external state,
inspection of safety-relevant accessories
 Internal inspection:
Inspection of opened plant section;
inspection of pressure-bearing walls,
inspection of installation conditions,
inspection of safety-relevant accessories;
and any supplementary inspections
(non-destructive testing)
 Strength test:
Inspection of closed-down plant section;
static pressure test with water / liquid

3 H. Gries, 2013/07
Legal Framework Conditions.
German Ordinance on Industrial Safety and Health - BetrSichV.

Periodic inspection of pressure equipment -

Alternative tests
(cf. §15 BetrSichV, TRBS 1201-2)

 Alternative / Substitute tests:

- Visual inspection visits
(during internal / external inspections)
- Pressure test (for strength tests)
may be replaced by suitable equivalent
methods (non-destructive testing),
when performance thereof is not possible
or is not appropriate.

4 H. Gries, 2013/07
Legal Framework Conditions.
German Ordinance on Industrial Safety and Health - BetrSichV.

Periodic inspection of pressure equipment -

Test intervals
(cf. §15 BetrSichV)

 Determination of test intervals by the operator

on the basis of a technical safety assessment
 Compliance with maximum test intervals

 Test intervals are to be specified

in such a manner
that continued safe operation
until the next periodic inspection is guaranteed.

5 H. Gries, 2013/07
Determination of Test Intervals.

Technical safety assessment procedure (cf. TRBS 1111)

1. Procure information
(on: manufacture, operation, condition)

6. Check effectiveness of
measures 2. Determine hazards
(damage;
bursting, release of media)

5. Implement measures 3. Assess hazards

(probability of occurrence, impact)

4. Specify measures
(type/ scope of inspections,
inspection intervals, inspectors)

6 H. Gries, 2013/07
Determination of Test Intervals.

Compliance with maximum test intervals (cf. §15 BetrSichV)

Pressure Equipment Maximum test intervals (years)
External inspection Internal inspection Strength test
Pressure vessels - 5 10

Heated pressure vessels/ 2 5 10

process steam boiler

Steam boiler 1 3 9

Pipelines 5 - 5
(flammable, corrosive, toxic
fluids)
Air cylinders for breathing 5 5 5
apparatus
Diving cylinders 2.5 2.5 5

Simple pressure vessels - 5 10

Gas fuel stations 5

Particular pressure equipment Specific requirements (cf. Annex 5 BetrSichV)

7 H. Gries, 2013/07
Legal Framework Conditions.
German Ordinance on Industrial Safety and Health - BetrSichV.

Periodic inspection of pressure equipment -

Due date of inspection (cf. §15 BetrSichV)

 Date for performance of an inspection: due month

(month of the initial inspection, prior to put into service)
 An inspection is still in due time
when it is performed within the tolerance period.
(2 months after the due month /
0–2 months before the due month)
 Performance of the inspection
before this tolerance period:
due month is postponed in future
to the month of performance
 Performance of the inspection
after this tolerance period:
not permitted and contrary to regulations
(possibility: official exemption by the authority)

8 H. Gries, 2013/07
Legal Framework Conditions.
German Ordinance on Industrial Safety and Health - BetrSichV.

Periodic inspection of pressure equipment -

Extension of test intervals
(cf. §15 BetrSichV)

 Extension of test intervals

In individual cases the responsible authority
can extend the intervals,
insofar as safety is guaranteed in some other way.

9 H. Gries, 2013/07
Extension of Test Interval. Official Exemption.

Possibility to extend the test interval

(cf. Guideline B 15.17 to BetrSichV, decree II4-8252.1/Kü of Ministry MAGS-NRW)

 Application made by the operator to the responsible authority:

- Application for extension of test interval
(valid for individual case / for a particular plant;
one-off or permanent extension)
- Concept for extension of test interval / technical safety assessment
(Measures to guarantee safety in some other way;
above the level of normal safety measures)
- Expert statement of an Authorised Inspection Agency (ZÜS)

 Official exemption
(valid as long as requirements are complied with)

 The test intervals are to be specified in such a manner

that the plant can be operated safely in the period of time between 2 inspections.

10 H. Gries, 2013/07
Extension of Test Interval.
Motivation / Case Study - Pressure Equipment.

Gas turbine and steam boiler of a combined cycle power plant (CCGT)

 Conventional test concept:

- Test intervals for the steam boiler: External inspection: 1 year
Internal inspection: 3 years
Strength test: 9 years
- Inspection cycle for the turbine: Inspection turbine: 4 years

 Alternative test concept:

- Internal inspection of steam boiler: extend from 3 to 4 years
- Strength test of steam boiler: reduce from 9 to 8 years
- Inspection cycle for the turbine: leave at 4 years

>> Through adjusting the test interval:

Expenditure reduced to 50 %

11 H. Gries, 2013/07
Extension of Test Interval.
Motivation / Case Study - Pressure Equipment.

Conventional test concept: 12 plant downtimes

Jahre 0 3 9 15 24

Alternative test concept : 6 plant downtimes

Internal inspection - steam boiler

Plant downtime Strength test - steam boiler
Inspection turbine

12 H. Gries, 2013/07
Extension of Test Interval. Procedure, Methods.

Test interval extension concept

 Process steps:
- Identification / Registration of all hazards / damage mechanisms
- Consideration of standard measures - for normal test intervals
- Stipulation of additional measures - for extended test intervals
(Measures that go beyond the state of the art:
in particular supplementary / additional tests, non-destructive testing, online monitoring,
status-oriented maintenance)
 Software tool of TÜV Rheinland (extract)

13 H. Gries, 2013/07
Supplementary Tests, Additional Tests, Substitute Tests.
Non-Destructive Testing (NDT).
Overview (cf. TRBS 1201-2, 2141-2)
Test Method
Damage RT RT pr UT cr UT wt MT / PT AT other
Wall material loss X X
Surface defects / X X X Industrial
cracks instrumentalisation,
potential probe
Volumetric defects X X
Weld imperfections X X X
Creep damage Industrial
instrumentalisation,
replica technique
Active defects / X
crack growing
Deformation Strain measurement

RT – Radiographic test UT – Ultrasonic test MT – Magnetic particle test

RT pr – Projection radiography (crack test, wall thickness test) PT – Penetration test
AT – Acoustic emission testing

14 H. Gries, 2013/07
Methods of Non-Destructive Materials Testing (NDT).

Visual Test (VT) Penetration Test (PT) Magnet. Part. Test (MT) Eddy Current Test (ET)

Surface (near to the surface)

Volume

Acoustic Emission (AT) Ultrasonic Test (UT) Radiographic Test (RT) Leak Test (LT)

15 H. Gries, 2013/07
Mobile Microstructure Evaluation On Site.

 Non-destructive (“mobile”) microstructure

evaluation of components on site through
microstructural replica technique
 Main application:
Creep damage in steam generation plants:
turbines, pipe bends, headers, fittings etc.
 Prompt evaluation, high resolution,
relatively cheap and quick
13CrMo4-4
Damage class 3b  Portrays the actual state of the component
linear porosity  Basis for
assessment of remaining lifetime

200:1

16 H. Gries, 2013/07
Strain Monitoring of High-Temperature Components.

 Creep behaviour of components

Kriechdehnung , %
0.4

0.3
(long-term measurement) 0.2
Bauteil A

 Short-term response
0.1

(start-up and shut-down) Austausch

Kriechdehnung , %
0.4

 Verification in cases of damage 0.3

0.2

 Off-line or online measurements 0.1

Bauteil B

 Material and component load 0 100.000

Zeit in Stunden
200.000

during operation

Creep

Short-term

17 H. Gries, 2013/07
Thank you for your attention.

TÜV Rheinland Industrie Service GmbH

Am Grauen Stein
51105 Köln
www.tuv.com

Herbert Gries
Tel. +49 221 806-2216
herbert.gries@de.tuv.com

18 H. Gries, 2013/07