AIM

1. Tata Projects
Quality Services-AIM
Date: 03-02-2016

2. 1. Scope of coverage
2. Definition of deliverables
3. Roles and responsibilities
4. Methodology- Condition assessment & Remaining life
assessment.
5. Case studies
6. Plan of action- proof of concept, phases, scaling
methodology and repeat of RLA cycle (long term
engagement).
TABLE OF CONTENTS

3. Scope: Condition Assessment & RLA
1. Industrial risk:
a. Identify: Damage mechanism
b. Assessment- Condition Assessment & RLA
c. Periodic Inspection at regular intervals

4. Definition of Deliverables
Recommendations :
- Maintain in operation as is / Re-rate
- For Repair
- Replace
- Inspection plan

5. 5
Methodology
Inputs from Plant / Client
Review of Design Data & Inputs
a)If authentic design data is available
b)If Not,Reverse Engineering will be done to establish the design
data with pre-bid inspection survey.
Team Of Experts for Pre BID Inspection Survey Involves –
1. Design Engg. 2. Inspection Expert 3. Static Eqpt. Expert
4. NDT Expert 5. Corrosion Expert

6. 6
Methodology
Inspection Data Analysis , evaluation & calculations
use as is, Repair, alteration and rerating
Planning of Site Visit –
Inspection, Examination and Testing
Recommendations on RLA & Condition Assessment

7. 7
1. General and local Metal loss
2. Surface connected cracking
3. Subsurface cracking
4. Micro fissuring/micro void formation
5. Metallurgical changes
6. Blistering
7. Dimensional Changes
8. Material properties changes
Modes of deterioration and Failure

8. 8
1. Internal Inspection
2. On-stream inspection
3. External Inspection
4. Thickness inspection
5. Corrosion under insulation
Types of inspection & Surveillance

9. 9
1.Fluorescent or dye penetrant examination
2.Magnetic Particle Examination
3.Radiographic Examination
4.Ultrasonic thickness measurement
5.Alternating current flux leakage examination
6.Eddy current examination
7.Field metallographic replication
8.Thermography
9.Pressure testing
10.Advanced NDT (PAUT, LRUT & TOFD)
11.Free run Tests
Examination technique

10. 10
1. Corrosion rate determination
2. Remaining life calculation
3. Maximum allowable working pressure determination
4. Condition assessment
5. Rerating of equipment.
Inspection Data Analysis & Evaluation

11. 11
Case Study
Remaining Life Assessment
of Pressure vessels

12. 12
Nitrogen Pressure Vessels
Received an Order from
Ambuja Cement for the
Residual Life Assessment of
Pressure vessels

13. 13
Nitrogen Pressure Vessels
Name of Manufacturer M/S MVS Engineering Ltd
Position Vertical
Dimensions
Dia 2.3 MTS x 10.7 MTRS
Length ,Shell 25mm thick
and Dish 25 mm thick
Material Carbon Steel
Drawing No. CL-223
Date on which first taken in use 2005
Safe Working Pressure
Recommended by manufacturer
25 kg/cm2
Date of last Examination 17/10/2011
Date of last NDT Examination 17/10/2011
Date of last Hydro Test Record 04/04/2011
Safe Working Pressure 25 Kg/sqcm

14. 14
Case Study
Condition Assessment of
KVK Nilachal Thermal power plant
Capacity: 1 x 350 MW

15. 15
Condition Assessment: Structural Stability
S. No. Area of Assessment
1 Boiler Pressure parts:
Boiler Drum,
Super heater tubes
Reheater tubes
Economiser tubes
Headers
Water wall panels
2 Boiler Structure
3 Boilers Structural Parts
4 Equipment :
Bowl mill
Hopper
5 ESP Structures erected

16. 16
Condition Assessment: Structural Stability
Sl.
No.
Civil: Area of Assessment
1 Turbine Generator Building
2 Chimney
3 Mill Foundation
4 Boiler Feed Pump foundation
5 ESP control Room
6 PA & FD Fan duct support foundation
7 ID fan foundation
8 Electrical Control Room
9 Power house building

17. 17
Condition Assessment: Structural Stability

18. 18
Materials Analysis and Examination

19. 19
7/19/2006
ULTRASONIC EXAMINATION
SCANNING DETAIL SHEET
SCANNING DETAIL
MH-3 (24” Manhole)
ID: 610mm
Thk: 105mm
Pad Plate: 60mm
View from I nside
MH10
Length: 22 mm (* ) (* * ) (Trans)
Depth: 2mm (case 8)
MH11
Length: 20mm
Depth: 17mm (case 7 or 8)
MH12
Length: 22 mm (* ) (* * ) (Trans)
Depth: 2mm (case 7)
MH01
Length: 70mm
Depth: 38mm (Case 7)
MH02
Length: 22 mm (* ) (Trans)
Depth: 2mm (case 7)
MH03
Length: 22 mm(* )(Trans)
Depth: 3mm (case 7)
MH04
Length: 30mm
Depth: 3mm
MH05
Length: 50mm
Depth: 10mm (case 8)
MH06 Two indications 40 mm &
170 mm (Does not appear to be
cracks, weld groove side wall-TWI)
MH08
Length: 180mm
Depth: 27mm (Case 9a)
MH09
Length: 22 mm (* ) (Trans)
Depth: 4mm
Weld
Weld
MH7a
Length 55 mm
(established by
visual and PT)
MH07b
Length: 20 mm
Depth: Through wall
established by UT (Case 9b)
MH07 Crack is visible from
outside at weld going towards 60 mm
tapered area (Case 9b).
75 mm
Note: The depth of crack in 55 mm length in weld and tapered section could not be established. The reason is anticipated
skewing of the beam or possibly attenuate the ultrasound altogether.
Length: 31 mm as
seen in photo
(*) Length from weld width
(* * ) MH10 & 12 as too close from
MH11
30mm
20mm
Rev 01

20. Condition Assessment & RLA –Benefits

21. Plan of Action

22. 22
References for Guideline
ASME Section V – NDT
ASME Section VIII Division I latest edition - Design & NDT
Acceptance
ASME FFS 1- Fitness for service
API 510-Press.Vessel Inspection code (Insp,rating,repair & alteration)
API 570-Piping Insp.( Inspection, rating, repair & alteration of in
process piping)
API 579 –Fitness for service
API 580-Risk Based Inspection
API 581 –Risk based inspection Technology
API 653 -Tank Inspection, Repair, Alteration, and Reconstruction

23. 23
THANK Q