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Report No.: N-24HS-PIPING
Inspector: Jeff Walling
Employer: Eagle Inspection
Inspection Date: 7/12/2010
ACME ChemicalsHouston, TX
High Pressure Steam (HS) Piping
API Certification No. 341
Building 24
System ID: 36
Inspector Signature
IN-SERVICE
Inspection Report For
An API Standard 570 Inspection that included visual (VT) and ultrasonic thickness (UT) examinations was conducted on the Building 24, HS piping system in the ACME Chemical facility located at Houston, TX. This system was originally built to ASME B31.1 construction code. This inspection was conducted in accordancewith requirements of the API-570 standard for inspections of in-service piping. The following is a detailed report of the inspection including findings and recommendations.
Report No.: N-24HS-PIPING
Page 1
3.0 INSPECTION RESULTS3.1 Leaks3.2 Misalignment3.3 Vibration3.4 Support3.5 Corrosion3.6 Insulation3.7 Other
4.0 RECOMMENDATIONS4.1 Leaks4.2 Misalignment4.3 Vibration4.4 Support4.5 Corrosion4.6 Insulation4.7 Other
5.0 ULTRASONIC THICKNESS MEASUREMENTS5.1 Results 5.2 Recommendations
1.0 EXECUTIVE SUMMARY
2.0 VESSEL DATA
TABLE OF CONTENTS
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDICIES Mechancial Integrity Calculations
Thickness Measurement Record
API 570 Inspection Checklist
Inspection Drawings
Inspection Photographs
APPENDIX F NDE Reports
APPENDIX G P&ID's
Report No.: N-24HS-PIPING
Page 2
1.0 EXECUTIVE SUMMARY
An API Standard 570 inspection of the building 24 HS (main steam) circuit 36, located at ACME Chemical in Houston, TX was conducted on 07/12 to 07/16/2010. This inspection was made to collect data in order to evaluate the mechanical integrity and fitness for service of the system. No major problems were noted during this inspection. Discrepancies are listed in Section 3.0 Inspection Results and 4.0 Recommendations.
SYSTEM DESCRIPTION: The HS steam system 36 provides high pressure steam to chiller turbines CH 24-1, CH 24-2 and CH 24-3 in building 24 and sub systems (MS and LS systems) through manifolds and regulators for supplied steam to the utility systems in other building (bldg 15, 2 , 3, et) via underground utility tunnels that run through out the facility. The source of steam comes from four 500lb steam boilers located in building 24.
HISTORICAL RECORDS: Inspections in accordance with ACME Class 1 ratings (visual exams every year) and RV bench tests (every two years) have been performed on this system routinely for the past decade. No previous UT measurements on the piping system were available
Next Inspection:7/13/2015Next Visual inspection is due by:
7/11/2020Next UT inspection is due by:
034Governing component limiting life:
Report No.: N-24HS-PIPING
Page 3
Service: High Pressure Steam (HS) Piping
Build Date: (yr) 1960
Circuit: System ID: 36
Diameter (in.): 10", 6" & 3" Mains
Sup. Span (ft.): 20
MAWP (psi): 520
Design Temp.: (ºF) 650
MDMT: (ºF) -20
Material Type: Ferritic Steels
Const Code: ASME B31.1
Oper. Press.: (psi) 450
2.0 PIPING DATA
Oper. Temp.: (ºF) 550
API Class: Class 2
ASME Category: Normal
Flange Rating: 600
Insulation Type: Calcium Silicate (12.5lb ^3ft)
Insulation Thk.: (in) 3
Pipe Spec: NA
Inspection Date: 7/12/2010
Report No.: N-24HS-PIPING
Page 4
3.1 Leaks:
3.1.1 There were two steam leaks through mechanical joints (flange and packing gland) found during this inspection (reference iso drawings #2 and #3). One is located on the Boiler #4 isolation valve and one at the distribution manifold on the North end in building 24.
3.1.2 There was water on the deck that appeared to be coming from the insulation below the valve station on line 24-HS-3-CS-C2-4 that goes to Chiller #2.
3.2 Misalignment:
3.2.1 No misalignment issues were noted at this inspection
3.3 Vibration:
3.3.1 No vibration issues were noted at this inspection.
3.0 INSPECTION RESULTSThe following results are the summarization of a field checklist that was utilized during the inspection of circuit System ID: 36
3.4 Supports:3.4.1 The line appears to be well supported. Much of the support structure was hidden from view, however where they were visible no coating failure or corrosion of the supports was observed.
3.5 Corrosion:3.5.1 The piping is carbons steel, well insulated and operating at above 300ºF and does not show signs of CUI or external corrosion.
3.6 Insulation:3.6.1 The HS piping is insulated with 3" CalSil block insulation and appears to be in satisfactory condition with minor breaks and openings through out the system.
3.7 Other:3.7.1 None
Report No.: N-24HS-PIPING
Page 5
4.1 Leaks:
4.1.1 Make efforts to repair the two steam leaks through mechanical joints (reference iso drawings #2 and #3) by tightening the packing gland, repacking, and/or replacing gasket as necessary.
4.1.2 Strip insulation from valve station on line 24-HS-3-CS-C2-4 that goes to Chiller #2 and check for possible steam leak in mechanical joints or other source of water from under insulation and make repairs as needed.
4.2 Misalignment:
4.2.1 None
4.3 Vibration:
4.3.1 None.
4.0 RECOMMENDATIONS
4.4 Supports:
4.4.1 None.
4.8 Next Inspection:7/13/20154.8.2 Next Visual inspection is due by
7/11/20204.8.3 Next UT inspection is due by
0344.8.4 Governing component limiting life
4.5 Corrosion:
4.5.1 None
4.6 Insulation:
4.6.1 Make repairs to insulation were needed through out the system to restore 100% coverage.
4.7 Other:
4.7.1 None
Report No.: N-24HS-PIPING
Page 6
5.1 Results Summary:
5.1.1 UT ports were required to be cut into the insulation to facilitate the UT examination of the HS piping system as designated by the API-Inspector. All Thickness measurements were above that required by ASME B31.1 Power Piping code requirements. All points examined have greater than twenty years remaining life with results showing moderate internal erosion-corrosion of the piping wall.
5.2 Recommendations:
5.2.1 Re-inspect piping system in 10 years in accordance with API-570 recommendations for Class II piping.
5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS
Report No.: N-24HS-PIPING
Page 7
APPENDIX A
1) Corrosion Rates
2) Remaining Life Calculations
3) Minimum Required Thickness Calculations
4) Structural Required Thickness Calculations
Mechancial Integrity Calculations
Report No.: N-24HS-PIPING
Page 8
Minimum Thickness Determinations:
a) The following pipe minimum thicknesses are based on the current in-house engineering standards, which take into consideration, pressures, structural integrity and localized corrosion allowance.
Size <=2" 3" 4" 6" 8" 10" 12" >12" t min
b) Large size pipe components or components subject to high pressures are calculated per the applicable construction code (i.e., ASME B31.3, para. 304 as follows: PD/2(SE+PY) = t)
PIPE COMPONENT REMAINING LIFEAPI-570 PIPING EVALUATION
Report No
N-24HS-PIPING
Inspector
Jeff Walling
Client
ACME Chemical
Circuit
System ID: 36
Date
7/12/2010
0.100 0.100 0.100 0.100 0.125 0.125 0.156 0.156
Size t prev t act t min Ca Cr RL
Pipe Component Remaining Life Calculations:
CML Line No. AgeSch6 0.432 0.454 0.143 0.311 0 >20001 24-HS-6-CS-B2-1 50806 0.432 0.304 0.143 0.161 0.00256 63002 24-HS-6-CS-B3-1 50806 0.432 0.281 0.143 0.138 0.00302 46003 24-HS-6-CS-B3-1 50806 0.432 0.299 0.143 0.156 0.00266 59004 24-HS-6-CS-B3-1 50806 0.432 0.438 0.143 0.295 0 >20005 24-HS-6-CS-B4-2 50806 0.432 0.682 0.143 0.539 0 >20006 24-HS-6-CS-B4-2 50806 0.432 0.428 0.143 0.285 8.0E-05 >20007 24-HS-6-CS-B4-2 50806 0.432 0.301 0.143 0.158 0.00262 60008 24-HS-6-CS-B4-2 50806 0.432 0.426 0.143 0.283 0.00012 2358009 24-HS-6-CS-MSH-3 508010 0.365 0.416 0.162 0.254 0 >20010 24-HS-10-CS-MSH-3 504010 0.365 0.403 0.162 0.241 0 >20011 24-HS-10-CS-MSH-3 504010 0.365 0.357 0.162 0.195 0.00016 1216012 24-HS-10-CS-MSH-3 504010 0.365 0.377 0.162 0.215 0 >20013 24-HS-10-CS-MSH-3 504010 0.365 0.321 0.162 0.159 0.00088 180014 24-HS-10-CS-MSH-3 504010 0.365 0.375 0.162 0.213 0 >20015 24-HS-10-CS-MSH-4 504010 0.365 0.367 0.162 0.205 0 >20016 24-HS-10-CS-MSH-4 504010 0.365 0.368 0.162 0.206 0 >20017 24-HS-10-CS-MSH-4 504010 0.365 0.462 0.162 0.300 0 >20018 24-HS-10-CS-MSH-4 504010 0.365 0.261 0.162 0.099 0.00208 47019 24-HS-10-CS-MSH-4 50406 0.432 0.382 0.143 0.239 0.001 239020 24-HS-6-CS-BP-4 508010 0.365 0.260 0.162 0.098 0.0021 46021 24-HS-10-CS-MSH-4 50406 0.432 0.424 0.143 0.281 0.00016 1756022 24-HS-6-CS-MSH-4 50806 0.432 0.424 0.143 0.281 0.00016 1756023 24-HS-6-CS-MSH-4 5080
N-24HS-PIPINGReport No.:
Page 9
Size t prev t act t min Ca Cr RL
Pipe Component Remaining Life Calculations:
CML Line No. AgeSch6 0.432 0.404 0.143 0.261 0.00056 466024 24-HS-6-CS-MSH-4 50806 0.432 0.377 0.143 0.234 0.0011 213025 24-HS-6-CS-BP-4 50806 0.432 0.403 0.143 0.260 0.00058 448026 24-HS-6-CS-MSH-4 50806 0.432 0.413 0.143 0.270 0.00038 711027 24-HS-6-CS-MSH-4 50806 0.432 0.282 0.143 0.139 0.003 46028 24-HS-6-CS-MSH-4 50806 0.432 0.396 0.143 0.253 0.00072 351029 24-HS-6-CS-MSH-4 50803 0.300 0.223 0.158 0.065 0.00154 42030 24-HS-3-CS-C3-4 50803 0.300 0.276 0.158 0.118 0.00048 246031 24-HS-3-CS-C3-4 50803 0.300 0.239 0.158 0.081 0.00122 66032 24-HS-3-CS-C2-4 50803 0.300 0.235 0.158 0.077 0.0013 59033 24-HS-3-CS-C2-4 50803 0.300 0.211 0.158 0.053 0.00178 30034 24-HS-3-CS-C2-4 50803 0.300 0.240 0.158 0.082 0.0012 68035 24-HS-3-CS-C1-4 50803 0.300 0.250 0.158 0.092 0.001 92036 24-HS-3-CS-C1-4 50806 0.432 0.495 0.143 0.352 0 >20037 24-HS-6-CS-B5-2 50806 0.432 0.478 0.143 0.335 0 >20038 24-HS-6-CS-B5-2 50806 0.432 0.540 0.143 0.397 0 >20039 24-HS-6-CS-B5-2 50806 0.432 0.591 0.143 0.448 0 >20040 24-HS-6-CS-MSH-4 508010 0.365 0.352 0.162 0.190 0.00026 729041 24-HS-10-CS-MSH-3 5040
N-24HS-PIPINGReport No.:
Page 10
Client: ACME Chemical
Date7/14/2010
PIPE COMPONENT PRESSURE CALCULATIONS
Project No.: 24HS-PIPINGASME B31.1 104.1
Outside Diameter, in. 6.625
Design Pressure, psi520.0
Joint Efficiency1
Stress, psi17000
Internal Pressure Minimum Thickness Calcs
Minimum Thickness, in. 0.100
Outside Diameter, in.
Minimum Thickness, in.
External Pressure Minimum Thickness CalculationsEffective Length, in. A
L/Do
Do/t
Thickness, in.0.101 Internal Pressure, psi524.7
Cu Ft4.525
Cylinder Capacities
Plate Data
Sq In
5836.8
Gals33.9
lb's ofWater 282.21
ProdS.G.0.01
Sq Ft
40.57
lb's of Prod.2.8
lb's of Steel714.3
MetalCu in 2521.5
Prod + Steel
717
Shell Length, in. 300
Shell Thickness, in0.432
Variables for Capacities
Total lb's
Shell Radius, in.2.881
Line No. 24-6-HS-CS-BP
D
P
E
S
t
L
t
Do
Internal Pressure Calculations
Pt = tnom - Ca =
Material A 106
Factor from Figure G
Thickness, in.
External Pressure CalculationsA
L/Do
Do/t
4B/3(Do/t) = Pa
t Factor from Figure G
Circuit 36
X-Chart
X-Chart
MAWP520
Temp.650
Ca0.331
S.H.0
Prod. SG0.01
Y 0.40 Coefficient
lbs/cu in0.2833
Material Catagory
CS/Crom. Stl
0.432tnomSize
6Sch
80
External Pressure, psiPa
B Stress Value
External Pressure, psiPa
B Stress Value
PD/2(SE+PY) = t
2SEt/D-2tY = P
Page 1 of 3Project No.: 24HS-PIPING Author: JLW
Page 11
Outside Diameter, in. 3.5
Design Pressure, psi520.0
Joint Efficiency1
Stress, psi17000
Internal Pressure Minimum Thickness Calcs
Minimum Thickness, in. 0.053
Outside Diameter, in.
Minimum Thickness, in.
External Pressure Minimum Thickness CalculationsEffective Length, in. A
L/Do
Do/t
Thickness, in.0.100 Internal Pressure, psi994.2
Cu Ft1.147
Cylinder Capacities
Plate Data
Sq In
3015.9
Gals8.58
lb's ofWater 71.511
ProdS.G.0.01
Sq Ft
20.96
lb's of Prod.0.7
lb's of Steel256.3
MetalCu in 904.78
Prod + Steel
257
Shell Length, in. 300
Shell Thickness, in0.300
Variables for Capacities
Total lb's
Shell Radius, in.1.45
Line No. 24-3-HS-CS-C1
D
P
E
S
t
L
t
Do
Internal Pressure Calculations
Pt = tnom - Ca =
Material A 106
Factor from Figure G
Thickness, in.
External Pressure CalculationsA
L/Do
Do/t
4B/3(Do/t) = Pa
t Factor from Figure G
Circuit 36
X-Chart
X-Chart
MAWP520
Temp.650
Ca0.200
S.H.0
Prod. SG0.01
Y 0.40 Coefficient
lbs/cu in0.2833
Material Catagory
CS/Crom. Stl
0.300tnomSize
3Sch
80
External Pressure, psiPa
B Stress Value
External Pressure, psiPa
B Stress Value
PD/2(SE+PY) = t
2SEt/D-2tY = P
Page 2 of 3Project No.: 24HS-PIPING Author: JLW
Page 12
Outside Diameter, in. 10.75
Design Pressure, psi520.0
Joint Efficiency1
Stress, psi17000
Internal Pressure Minimum Thickness Calcs
Minimum Thickness, in. 0.162
Outside Diameter, in.
Minimum Thickness, in.
External Pressure Minimum Thickness CalculationsEffective Length, in. A
L/Do
Do/t
Thickness, in.0.163 Internal Pressure, psi521.9
Cu Ft13.69
Cylinder Capacities
Plate Data
Sq In
9787.6
Gals102
lb's ofWater 853.72
ProdS.G.0.01
Sq Ft
68.02
lb's of Prod.8.5
lb's of Steel1012.1
MetalCu in 3572.5
Prod + Steel
1021
Shell Length, in. 300
Shell Thickness, in0.365
Variables for Capacities
Total lb's
Shell Radius, in.5.01
Line No. 24-10-HS-CS-MSH
D
P
E
S
t
L
t
Do
Internal Pressure Calculations
Pt = tnom - Ca =
Material A 106
Factor from Figure G
Thickness, in.
External Pressure CalculationsA
L/Do
Do/t
4B/3(Do/t) = Pa
t Factor from Figure G
Circuit 36
X-Chart
X-Chart
MAWP520
Temp.650
Ca0.202
S.H.0
Prod. SG0.01
Y 0.40 Coefficient
lbs/cu in0.2833
Material Catagory
CS/Crom. Stl
0.365tnomSize
10Sch
40
External Pressure, psiPa
B Stress Value
External Pressure, psiPa
B Stress Value
PD/2(SE+PY) = t
2SEt/D-2tY = P
Page 3 of 3Project No.: 24HS-PIPING Author: JLW
Page 13
Tk 3.00 Wt. 7.13 TIW 142.6
Quantity 2Lbs81
Quantity 1Lbs720 Total Valve Weight 720.0
Total Flange Weight 162.0
Wt. 0Other Load 0 TOW 0.0Quantity 0
Flange WeightValve Weight
in.Insul. Calcium Silicate
R 3.313r 2.881SG 0.01Ss 240L 1025S 17000ca 0.000
W1 2.381
W2 0.009
Mo1 61476
Mo2 78688
t 0.143
Outside Radius (in.)
Inside Radius (in.)
Center Load (lbs)
Material Sress (psi)
Corrosion allowance (in.)
Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)
Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)
Max Bending Moment (in.-lbs)(Mo1+[W1+W2]*Ss*[Ss/8])
Minumum Required thickness (in.)([R]-[[R^4]-[[R*Mo2*4/[S*Pi]]]^.25)+ca
Load Bending Moment (in.-lbs) (Ss*L)/4)
Tw 1031 Total Support Load (lbs)
Rn 2 Number of Rods/Pipe Support
Rod Sizes (Dia.)
Load/Rod
SL 2260 Support Load Max (lbs)
Piping Support Sufficient
Pipe hanger load evaluation (ASTM A36 or A575)
480Supported Length
46 % Stressed
Valves0
Flanges0
Other Wt0
Total Load285.2
Ins. Wt285.2
Support Spacing (in.)
Rs 0.50
ML 1130
NOTES:
Lb/Ft
lbs/cu in0.2833CS/Crom. StlMaterial Catagory
Da in.
Company, Line#ACME Chemical, 24-6-HS-CS
Temp.°F650A 106
Material
Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010
Wm
Superheated HP Steam
t nom0.432
OD6.625
Size
6Sch
80
0
Project : 24HS-PIPING Company, Line# ACME Chemical, 24-6-HS-CS
Page 14
Tk 2.00 Wt. 2.84 TIW 56.8
Quantity 2Lbs23
Quantity 1Lbs170 Total Valve Weight 170.0
Total Flange Weight 46.0
Wt. 0Other Load 0 TOW 0.0Quantity 0
Flange WeightValve Weight
in.Insul. Calcium Silicate
R 1.750r 1.450SG 0.01Ss 240L 273S 17000ca 0.000
W1 0.854
W2 0.002
Mo1 16368
Mo2 22537
t 0.158
Outside Radius (in.)
Inside Radius (in.)
Center Load (lbs)
Material Sress (psi)
Corrosion allowance (in.)
Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)
Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)
Max Bending Moment (in.-lbs)(Mo1+[W1+W2]*Ss*[Ss/8])
Minumum Required thickness (in.)([R]-[[R^4]-[[R*Mo2*4/[S*Pi]]]^.25)+ca
Load Bending Moment (in.-lbs) (Ss*L)/4)
Tw 597 Total Support Load (lbs)
Rn 2 Number of Rods/Pipe Support
Rod Sizes (Dia.)
Load/Rod
SL 1220 Support Load Max (lbs)
Piping Support Sufficient
Pipe hanger load evaluation (ASTM A36 or A575)
480Supported Length
49 % Stressed
Valves1
Flanges2
Other Wt0
Total Load329.6
Ins. Wt113.6
Support Spacing (in.)
Rs 0.375
ML 610
NOTES:
Lb/Ft
lbs/cu in0.2833CS/Crom. StlMaterial Catagory
Da in.
Company, Line#ACME Chemical, 24-3-HS-CS
Temp.°F650A 106
Material
Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010
Wm
Superheated HP Steam
t nom0.300
OD3.5
Size
3Sch
80
0
Project : 24HS-PIPING Company, Line# ACME Chemical, 24-3-HS-CS
Page 15
Tk 3.00 Wt. 10.5 TIW 210.0
Quantity 2Lbs190
Quantity 1Lbs1880 Total Valve Weight 1880.0
Total Flange Weight 380.0
Wt. 0Other Load 0 TOW 0.0Quantity 0
Flange WeightValve Weight
in.Insul. Calcium Silicate
R 5.375r 5.010SG 0.01Ss 240L 2470S 17000ca 0.000
W1 3.374
W2 0.028
Mo1 148200
Mo2 172695
t 0.116
Outside Radius (in.)
Inside Radius (in.)
Center Load (lbs)
Material Sress (psi)
Corrosion allowance (in.)
Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)
Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)
Max Bending Moment (in.-lbs)(Mo1+[W1+W2]*Ss*[Ss/8])
Minumum Required thickness (in.)([R]-[[R^4]-[[R*Mo2*4/[S*Pi]]]^.25)+ca
Load Bending Moment (in.-lbs) (Ss*L)/4)
Tw 1481 Total Support Load (lbs)
Rn 2 Number of Rods/Pipe Support
Rod Sizes (Dia.)
Load/Rod
SL 2260 Support Load Max (lbs)
Piping Support Sufficient
Pipe hanger load evaluation (ASTM A36 or A575)
480Supported Length
66 % Stressed
Valves0
Flanges0
Other Wt0
Total Load420
Ins. Wt420
Support Spacing (in.)
Rs 0.50
ML 1130
NOTES:
Lb/Ft
lbs/cu in0.2833CS/Crom. StlMaterial Catagory
Da in.
Company, Line#ACME Chemical, 24-10-HS-CS
Temp.°F650A 106
Material
Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010
Wm
Superheated HP Steam
t nom0.365
OD10.75
Size
10Sch
40
0
Project : 24HS-PIPING Company, Line# ACME Chemical, 24-10-HS-CS
Page 16
Component Thickness Measurements (in inches)
Components with Vert. Axis: tml-1 N., tml-2 E., tml-3 S., tml-4 W. (Drawing N.)
Components with Horz. Axis: tml-1 Top, tml-2 Side, tml-3 Bttm., tml-4 Side (Clock Wise)
Piping Inspection DataAPI-570 PIPING EVALUATION
Report No
N-24HS-PIPING
Inspector
Jeff Walling
Client
ACME Chem.
Circuit
Circuit 36
Date
7/12/2010
Size Comp. DiscLine No. tml-1 tml-2 tml-3 tml-4 t actCML #6 Elbow 45°24-HS-6-CS-B2-1 0.454 0.454001
6 Elbow 90°24-HS-6-CS-B3-1 0.304 0.304002
6 Elbow 90°24-HS-6-CS-B3-1 0.281 0.281003
6 Elbow 90°24-HS-6-CS-B3-1 0.299 0.299004
6 Elbow 90°24-HS-6-CS-B4-2 0.438 0.438005
6 Elbow 90°24-HS-6-CS-B4-2 0.682 0.682006
6 Straight Pipe24-HS-6-CS-B4-2 0.428 0.462 0.428007
6 Elbow 90°24-HS-6-CS-B4-2 0.301 0.301008
6 Straight Pipe24-HS-6-CS-MSH-3 0.426 0.426009
10 Elbow 90°24-HS-10-CS-MSH-3 0.416 0.416010
10 Elbow 90°24-HS-10-CS-MSH-3 0.403 0.403011
10 Elbow 90°24-HS-10-CS-MSH-3 0.357 0.357012
10 Tee Fitting24-HS-10-CS-MSH-3 0.377 0.377013
10 Straight Pipe24-HS-10-CS-MSH-3 0.321 0.338 0.357 0.321014
10 Straight Pipe24-HS-10-CS-MSH-4 0.413 0.375 0.400 0.375015
10 Straight Pipe24-HS-10-CS-MSH-4 0.367 0.367016
10 Straight Pipe24-HS-10-CS-MSH-4 0.368 0.368017
10 Straight Pipe24-HS-10-CS-MSH-4 0.462 0.462018
10 Straight Pipe24-HS-10-CS-MSH-4 0.261 0.261019
6 Elbow 90°24-HS-6-CS-BP-4 0.382 0.382020
10 Straight Pipe24-HS-10-CS-MSH-4 0.260 0.260021
Report No.: 24HS-PIPING
Page 18
Size Comp. DiscLine No. tml-1 tml-2 tml-3 tml-4 t actCML #6 Elbow 90°24-HS-6-CS-MSH-4 0.424 0.424022
6 Straight Pipe24-HS-6-CS-MSH-4 0.424 0.431 0.437 0.424023
6 Straight Pipe24-HS-6-CS-MSH-4 0.450 0.445 0.404 0.404024
6 Elbow 90°24-HS-6-CS-BP-4 0.377 0.377025
6 Straight Pipe24-HS-6-CS-MSH-4 0.418 0.403 0.403026
6 Straight Pipe24-HS-6-CS-MSH-4 0.432 0.431 0.413 0.413027
6 Elbow 90°24-HS-6-CS-MSH-4 0.282 0.282028
6 Elbow 90°24-HS-6-CS-MSH-4 0.396 0.396029
3 Elbow 90°24-HS-3-CS-C3-4 0.223 0.223030
3 Straight Pipe24-HS-3-CS-C3-4 0.276 0.276031
3 Elbow 90°24-HS-3-CS-C2-4 0.239 0.239032
3 Elbow 90°24-HS-3-CS-C2-4 0.241 0.235 0.259 0.235033
3 Straight Pipe24-HS-3-CS-C2-4 0.211 0.211034
3 Elbow 90°24-HS-3-CS-C1-4 0.240 0.240035
3 Straight Pipe24-HS-3-CS-C1-4 0.250 0.268 0.255 0.250036
6 Elbow 90°24-HS-6-CS-B5-2 0.495 0.495037
6 Straight Pipe24-HS-6-CS-B5-2 0.504 0.478 0.478038
6 Elbow 90°24-HS-6-CS-B5-2 0.540 0.540039
6 Tee Fitting24-HS-6-CS-MSH-4 0.591 0.591040
10 Tee Fitting24-HS-10-CS-MSH-3 0.352 0.352041
Report No.: 24HS-PIPING
Page 19
Company: ACME ChemicalIso No: 24-HS-3
Report No.: 24HS-PIPING Date: 7/12/2010
Inspector: Jeff WallingCert No.: 0341
API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-10-CS-MSH
ITEM
Notes:Insulation 3" CalSil
ACCEPTABLE UNACCEPTABLE N/A COMMENTSLEAKS?
Process
Steam tracing
Existing clamps
MISALIGNMENT?
Pipe misalignment/restriction
Expansion joint alignment
VIBRATIONS?
Excessive overhung weight
Supports
Thin, small-bore alloy piping
Threaded connections
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Slide plates/rollers
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Soil-to-air interface
Insulation interface
Biological growth
INSULATION?
Damage/penetrations
Missing jacketing/insulation
Sealing deterioration
Bulging
Banding broken/missing
flange leak on manifold iso valve
where visible, no sig. distortion or corrosion
minor spotsminor spots
Page 1 of 4
Page 21
Company: ACME ChemicalIso No: 24-HS-4
Report No.: 24HS-PIPING Date: 7/12/2010
Inspector: Jeff WallingCert No.: 0341
API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-10-CS-MSH
ITEM
Notes:Insulation 3" CalSil
ACCEPTABLE UNACCEPTABLE N/A COMMENTSLEAKS?
Process
Steam tracing
Existing clamps
MISALIGNMENT?
Pipe misalignment/restriction
Expansion joint alignment
VIBRATIONS?
Excessive overhung weight
Supports
Thin, small-bore alloy piping
Threaded connections
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Slide plates/rollers
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Soil-to-air interface
Insulation interface
Biological growth
INSULATION?
Damage/penetrations
Missing jacketing/insulation
Sealing deterioration
Bulging
Banding broken/missing
where visible, no sig. distortion or corrosion
minor spotsminor spots
Page 2 of 4
Page 22
Company: ACME ChemicalIso No: 24-HS-1
Report No.: 24HS-PIPING Date: 7/12/2010
Inspector: Jeff WallingCert No.: 0341
API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-6-CS-B2/3
ITEM
Notes:Insulation 3" CalSil
ACCEPTABLE UNACCEPTABLE N/A COMMENTSLEAKS?
Process
Steam tracing
Existing clamps
MISALIGNMENT?
Pipe misalignment/restriction
Expansion joint alignment
VIBRATIONS?
Excessive overhung weight
Supports
Thin, small-bore alloy piping
Threaded connections
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Slide plates/rollers
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Soil-to-air interface
Insulation interface
Biological growth
INSULATION?
Damage/penetrations
Missing jacketing/insulation
Sealing deterioration
Bulging
Banding broken/missing
where visible, no sig. distortion or corrosion
minor spotsminor spots
Page 3 of 4
Page 23
Company: ACME ChemicalIso No: 24-HS-2
Report No.: 24HS-PIPING Date: 7/12/2010
Inspector: Jeff WallingCert No.: 0341
API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-6-CS-B4/5
ITEM
Notes:Insulation 3" CalSil
ACCEPTABLE UNACCEPTABLE N/A COMMENTSLEAKS?
Process
Steam tracing
Existing clamps
MISALIGNMENT?
Pipe misalignment/restriction
Expansion joint alignment
VIBRATIONS?
Excessive overhung weight
Supports
Thin, small-bore alloy piping
Threaded connections
SUPPORTS?
Shoes
Hanger distortion
Spring Hangers
Bracing
Brackets
Slide plates/rollers
Counter balance
Support corrosion
CORROSION?
Crevice
Coating
Soil-to-air interface
Insulation interface
Biological growth
INSULATION?
Damage/penetrations
Missing jacketing/insulation
Sealing deterioration
Bulging
Banding broken/missing
valve stem leak on #4 boiler iso valve
where visible, no sig. distortion or corrosion
minor spotsminor spots
Page 4 of 4
Page 24
ACME CHEMICAL BLDG 24 – HIGH PRESSURE STEAM (HS) REPORT – N-24HS-PIPING INSPECTION PHOTOGRAPHS
Boiler #4 line 24-HS-6-CS-B4-1 (typical to all boilers)
Missing insulation HS Main
Page 31
ACME CHEMICAL BLDG 24 – HIGH PRESSURE STEAM (HS) REPORT – N-24HS-PIPING INSPECTION PHOTOGRAPHS
Boiler #2 line 24-HS-6-CS-B2-1 (missing insulation)
Page 32
ACME CHEMICAL BLDG 24 – HIGH PRESSURE STEAM (HS) REPORT – N-24HS-PIPING INSPECTION PHOTOGRAPHS
Distribution Manifold 24-HS-10-CS-MSH-3 (flange joint steam leak)
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ACME CHEMICAL BLDG 24 – HIGH PRESSURE STEAM (HS) REPORT – N-24HS-PIPING INSPECTION PHOTOGRAPHS
By pass line 24-HS-6-CS-BP-4
Main Steam Header 24-HS-10-CS-MSH-4
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ACME CHEMICAL BLDG 24 – HIGH PRESSURE STEAM (HS) REPORT – N-24HS-PIPING INSPECTION PHOTOGRAPHS
Main Steam Header expansion loop 24-HS-6-CS-MSH-4
HS to Chiller #2, line - 24-HS-6-CS-C2-4
Page 35
APPENDIX F
1) UT Calabration Report
2) NDE Technician Certification
3) API-570 Inspector Certification
NDE Reports
Report No.: NASA-24HS-PIPING
Page 36
ULTRASONIC EXAMINATION REPORT CLIENT: ACME Chemicals CLIENT PO #: 10002-001 REPORT NO.: N-24HS-PIPING EIT JOB #: 10032 EQUIP ID: HS Piping Bld 24 SERVICE: High Pressure Steam JOB DESCR.: 330 ft high pressure steam piping thickness readings. EXAM DATE: 07/16/2010 PROCEDURE #: EIT-UTT-01 SPECIFICATION: API-570 MATERIAL: CS
TEST PARAMETERS
UT UNIT Unit: Panameterics DL37+ S/N: 5904 Cal Date: 11/11/09
PROBE SPECIFICATIONS Long Frq 5 mHZ Size: .375 Type: D790 S/N 905216 SW Frq: mHZ Size: Type: S/N SW Frq: mHZ Size: Type: S/N SW Frq: mHZ Size: Type: S/N
COUPLANT MFG: Ultra Grade Gel-40 Surface Cond: Coated
CALIBRATION STANDARD Type: Raycheck 6 Step Block S/N: 00-7235
Calibration Reference Level (db) 0: 51 45: 60: 70: Other: 0: 45: 60: 70: Start Time: 0800 End Time: 1200 Start Time: End Time:
Results/Comments: Reference API-570 Report UT Level II Technician: Jeff Walling
Page 37
NAME:
METHOD LEVEL DATE EXAMINER GENERAL SPECIFIC PRACTICAL COMPOSITEUTT II 4/9/2010 Joe Monroe 86% 100% 95% 94% 4/9/2015PT II 9/3/2010 Wayne Bailey 93% 95% 91% 93% 9/3/2015MT II 9/3/2010 Wayne Bailey 93% 95% 85% 91% 9/3/2015
MFE II 1/21/2011 Brian Rotto 90% 85% 89% 88% 1/21/2016
FROM TO6/2009 9/2013
1/19/2004 11/20/20099/1/1998 4/15/2003
9/16/1995 9/1/1998
EAGLE I. TECHNOLOGIES Jeffrey WallingNDT CERTIFICATION / QUALIFICATION RECORD Employee ID Number: 3965
NDT CERTIFICATIONS EXAM SCORES EXPIRATION DATE RESTRICTIONS
thickness onlyNoneNoneNone
PREVIOUS EMPLOYER NDT CERTIFICATIONSCOMPANY NAME/ADDRESS NDT METHODS & HIGHEST LEVEL ATTAINED
Westech Inspection Level II UT thickness limitedBP/GIANT Level II UTT/MT/PT/LT
MATIS Level II UTT/MT/PT
CAPE Level II UTT/MT/PT/MFE
EYE EXAMINATION EDUCATION AND TRAININGDATE TYPE TESTED BY PASS / FAIL ORG DATE LENGTH
10/22/2012 Far Amer. Best Pass MATIS 12/16/1997 12 hours10/22/2012 Near Amer. Best Pass MATIS 12/16/1997 12 hours10/22/2012 Color Contrast Amer. Best Pass Eastern NDT 4/9/2010 24 hours
WCFS 8/25/2010 20 hoursWCFS 8/27/2010 12 hoursCAPE 1/21/2011 8 hours
CERT EXP DATE CERT EXP DATEAPI 653 4/30/2014 PD DEP 1/10/2016
API 510 6/30/2014 NB Comm. 2014API 570 6/30/2014 VA-B&PV Com 2013 HOURS
STI 9/18/2017 MET.AS 2012
-ASNT
CERT No.
10/22/2012DATE
INSTRUCTOR SUBJECTDavid Spooner Level II UTT
Joe Monroe Level II UTTDavid Spooner Level II PT
refer to employee eye exam cert (CAPE-FRM-101) Stan Meyer Level II MT
OTHER NOTABLE CERTIFICATIONS OR QUALIFICATIONS
Stan Meyer Level II PTBrian Rotto Level II MFE
TRAINEE / LEVEL I NDT HOURS (IF APPLICABLE)METHOD EMPLOYER TOTAL DATE
Jeff Walling
This NDT Qualification record is in accordance with EIT-WP-01 and SNT-TC-1A (2006). All historical information supplied for this document is true and accurate to the best of my knowledge.SIGNATURE
EIT Certification Record Form: CAPE-FRM-102
NDE PROGRAM MANAGER
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