Presentation on Sharing of Research Project Seminar TNBR QATS: Involve to Solve April 2017
Power Piping Displacement Measurement & Monitoring System at Power Plant
Mohd Hafiz Bin Abdul Ghaffar Researcher Materials Engineering Group TNB Research
Introduction • ASME B31.1 Chapter VII – Operation and Maintenance, Section 144 CPS WALKDOWNS [1] • “The Operating Company shall evaluate the effects of unexpected piping position changes, significant vibrations, and malfunctioning supports on the piping system’s integrity and safety”. • “Significant displacement variations from the expected design displacements shall be considered to assess the piping system’s integrity”
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Background
Suspended beam is not balanced, slanted to the other side
Fig.1. Damaged Pipe Hanger
•
Power piping system is one of the critical components that need attention as it operates at elevated temperature and high pressure
•
Weight, thermal expansion of the pipe generates enormous force and stress in the system
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Pipe hangers/supports are to minimize & maintain the system stresses to be within the allowable limit & allow sufficient movement [1].
•
Sudden change in operation load, upset & transient event, causes dramatic pipe displacement can lead performance degradation & malfunction, further induce high stress on piping system [2].
•
One way to prevent pipe hanger malfunction is to have continuous monitoring of pipe displacement.
Fig. 2. Pipe crack near elbow.
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Background (2) •
The addition of mandatory Chapter VII to ASME B31.1 communicated to the industry the need to perform pipe support walkdown at hot and cold condition [3], read and record piping system displacements as part of the piping and pipe support maintenance program.
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Periodic monitoring and walk down has limitation in capturing pipe position: visual inspections are only spot check- pipe position is recorded only at the time of inspection. horizontal movement of the pipe remains unknown Reading data from distance due to inaccessible pipe hanger cause inaccurate hanger reading & lead to incorrect pipe movement
•
Gaining access to the hard-to-reach hangers, reading data from a distance, necessitate other technique of pipe displacement survey/monitoring to be used
Fig.4. Pipe hanger reading during hanger walk down
Fig.5. Inaccessible pipe hanger during walk down
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Overview of the Pipe Displacement Monitoring System Piping Site
Plant
PLUMBER Server
Transducers
Engineers’ Room
Clamp at fixed structure: beam
Clamp at pipe hanger clamp
Fig. 6. 3DDMS transducer
Turbine Hall
Monitoring
Fig. 7. Schematic diagram of 3DDMS and PLUMBER system
• Transducers installed on piping system (at site). • PLUMBER (system server) placed near turbine hall. 5 Copyright © 2017 TNB Research
Benefit The benefit is aspired from the continuous pipe movement capture and monitoring, early issues identifying Capture Pipe Movement: Magnitude & Direction
3DDMS on Power Piping System
Continuous Pipe Movement Monitoring
Benefits •
• •
Detection of Abnormality
•
Sudden, fluctuated abnormal movement due to transient/upset event can be captured, aids in identifying issues early Significant displacement variations from the expected design displacement can be detected As a means to support identification of critical locations for inspection & assessment Can be part of the pipe support program development
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Case Study: Power Piping Displacement Monitoring 5&6
2 T6 T8
T5 1
T1
T3
T2
T7
T4
3&4
7
• Transducer locations on Main Steam pipe Copyright © 2017 TNB Research
8
7
Case Study: Power Piping Displacement Monitoring
Displacement trending
Temperature trending PLUMBER Piping 3D Visual
• Trend View exhibits pipe movement trending for specified period of time including history trending • Pipe design movement & pipe movement limits can be integrated in the trending for reference & monitoring purpose 8 Copyright © 2017 TNB Research
Case Study: Power Piping Displacement Monitoring 6
8
5 15
5
37
37
7
y
z August 2016 to December 2016
x
22 52
Pipe displacement in x- (blue), y- (red) and z-axis (green)
• 3DDMS (Transducer) data showed unsynchronized pipe movement in y- and z-axis of 3DDMS Location 7 & 8. • Pipe actual movement difference has exceeded the design movement difference. • Unsynchronized movement in y- and z-axis of north & south pipe could create high stress on weldment of H-joint. 9
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Visual Inspection
MSP (Left)
CRH
• MSP cladding is in contact with beam structure • Figure shows beam structure is penetrated into MSP cladding (near to 3DDMS location 8), this could probably disturb pipe movement 10 Copyright © 2017 TNB Research
Conclusion • Hanger survey & piping inspection are key to monitoring power piping system as pipe support/hanger malfunction is the first sign of trouble, cause elevated stress, the displacement measurement system can greatly contribute to the piping system safety and reliability
• The displacement measurement system is able to continuously capture and monitor pipe displacement during normal operation and transient, aids in identifying issue • Significant displacement variations from the expected design displacement can be detected and considered in assessment of piping system integrity as recommended in ASME B31.1 • As a means to support identification of critical locations for piping inspection & assessment 11 Copyright © 2017 TNB Research
THANK YOU Prepared by : [Mohd Hafiz Bin Abdul Ghaffar]
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[email protected] / Website: www.tnbr.com.my
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