Report Pipe

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.


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


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:


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


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


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


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


Page 7

APPENDIX A

1) Corrosion Rates

2) Remaining Life Calculations

3) Minimum Required Thickness Calculations

4) Structural Required Thickness Calculations

Mechancial Integrity Calculations


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


B Stress Value

PD/2(SE+PY) = t

2SEt/D-2tY = P

Page 1 of 3Project No.: 24HS-PIPING Author: JLW

Page 11



Joint Efficiency1

Stress, psi17000






L/Do

Do/t


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




Total lb's


Line No. 24-3-HS-CS-C1

D

P

E

S

t

L

t

Do


Pt = tnom - Ca =

Material A 106


Thickness, in.


L/Do

Do/t

4B/3(Do/t) = Pa


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


B Stress Value


B Stress Value

PD/2(SE+PY) = t

2SEt/D-2tY = P


Page 12



Joint Efficiency1

Stress, psi17000






L/Do

Do/t


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




Total lb's


Line No. 24-10-HS-CS-MSH

D

P

E

S

t

L

t

Do


Pt = tnom - Ca =

Material A 106


Thickness, in.


L/Do

Do/t

4B/3(Do/t) = Pa


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


B Stress Value


B Stress Value

PD/2(SE+PY) = t

2SEt/D-2tY = P


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






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


Inside Radius (in.)

Center Load (lbs)










Rod Sizes (Dia.)

Load/Rod




480Supported Length

49 % Stressed

Valves1

Flanges2

Other Wt0

Total Load329.6

Ins. Wt113.6


Rs 0.375

ML 610

NOTES:

Lb/Ft


Da in.


Temp.°F650A 106

Material


Wm


t nom0.300

OD3.5

Size

3Sch

80

0


Page 15

Tk 3.00 Wt. 10.5 TIW 210.0

Quantity 2Lbs190






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


Inside Radius (in.)

Center Load (lbs)










Rod Sizes (Dia.)

Load/Rod




480Supported Length

66 % Stressed

Valves0

Flanges0

Other Wt0

Total Load420

Ins. Wt420


Rs 0.50

ML 1130

NOTES:

Lb/Ft


Da in.


Temp.°F650A 106

Material


Wm


t nom0.365

OD10.75

Size

10Sch

40

0


Page 16

APPENDIX B

Thickness Measurement Record


Page 17

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






6 Elbow 90°24-HS-6-CS-BP-4 0.382 0.382020


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 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 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



Report No.: 24HS-PIPING

Page 19

APPENDIX C

API 570 Inspection Checklist

Page 20

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




API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-10-CS-MSH

ITEM



Process

Steam tracing

Existing clamps

MISALIGNMENT?



VIBRATIONS?


Supports



SUPPORTS?

Shoes

Hanger distortion

Spring Hangers

Bracing

Brackets


Counter balance

Support corrosion

CORROSION?

Crevice

Coating



Biological growth

INSULATION?

Damage/penetrations



Bulging




Page 2 of 4

Page 22




API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-6-CS-B2/3

ITEM



Process

Steam tracing

Existing clamps

MISALIGNMENT?



VIBRATIONS?


Supports



SUPPORTS?

Shoes

Hanger distortion

Spring Hangers

Bracing

Brackets


Counter balance

Support corrosion

CORROSION?

Crevice

Coating



Biological growth

INSULATION?

Damage/penetrations



Bulging




Page 3 of 4

Page 23




API-570 PIPING INSPECTION CHECKLISTLine No: 24-HS-6-CS-B4/5

ITEM



Process

Steam tracing

Existing clamps

MISALIGNMENT?



VIBRATIONS?


Supports



SUPPORTS?

Shoes

Hanger distortion

Spring Hangers

Bracing

Brackets


Counter balance

Support corrosion

CORROSION?

Crevice

Coating



Biological growth

INSULATION?

Damage/penetrations



Bulging


valve stem leak on #4 boiler iso valve



Page 4 of 4

Page 24

APPENDIX D

Inspection Drawings

Report No.: NASA-24HS-PIPING

Page 25

Page 26

Page 27

Page 28

Page 29

APPENDIX E

Inspection Photographs


Page 30

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


Boiler #2 line 24-HS-6-CS-B2-1 (missing insulation)

Page 32


Distribution Manifold 24-HS-10-CS-MSH-3 (flange joint steam leak)

Page 33


By pass line 24-HS-6-CS-BP-4

Main Steam Header 24-HS-10-CS-MSH-4

Page 34


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


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

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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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APPENDIX G

P&ID's


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Documents

Report Pipe