inspection of distribution piping systems: a risk based
TRANSCRIPT
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Inspection of Distribution
Piping Systems: A Risk
Based Approach
IDEA’s 27th Campus Energy
Conference
February 18-21, 2014
Atlanta
Joe Maciejczyk, PE
Structural Integrity Associates
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Why inspect?
RISK
KNOWING
WHERE
YOU ARE
“CORROSION
NEVER SLEEPS”
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Why inspect?
RISK
PERSONNEL SAFETY!
Risk from unknown hazards
Protection from negligence claims
Disruptions
Unbudgeted expenditures
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Forced Maintenance
• End user disruptions
• Loss of efficiency
• Safety issues
• Unbudgeted Expenditures
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Why inspect?
KNOWING
WHERE
YOU ARE INFRASTRUCTURE CONDITION
PLANNING
NEW
CONSTRUCTION
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Why inspect?
“CORROSION
NEVER SLEEPS”
SELECTIVE WELD ATTACK
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Damage Mechanisms
- Corrosion
- Eternal (protection system failure)
- Internal (water chemistry issues)
- Corrosion under insulation
- MIC (Microbial induced)
- Erosion
- Flow induced
- Particulate
- Stresses
- Low cycle thermal fatigue (start-ups/shut-downs)
- Primary pressure (wall loss)
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Traditional Piping
Inspection Programs
• Exception based
– No inspection program unless failure (forensic vs. proactive)
– Reactionary mode
– Opportunity driven
• Ease of access
– Out of sight, out of mind (buried, vaulted, cased)
– Insulation concerns
– Safety
• Limited review
– Point selection
– Selection basis
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Diverse Infrastructure
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Localized Issues
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RISK
BASED
PROGRAM
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Risk Based Program
• Data Collection
• Definition of Corrosion Segments
• Risk Assessment
• Inspections
• Program Maintenance
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Risk Based Program
Data Collection • Piping drawings - compilation and review of drawings
• Structural details
• Support and anchor details
• Piping Specifications
• Flow diagrams
• P&ID diagrams
• Failure history
• Past Inspection results
• Repair history
• Water treatment - assembly of water chemistry and water chemistry history,
and water treatment and treatment history
• Leakage history
• Cathodic protection history including coating inspections
• ID cleaning history
• System walkdowns
• Safety record (e.g. near miss incidents, etc.)
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Risk Based Program
• Define segments
Corrosion Segment Definition
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Prioritization Examples
High Risk Zones/Services
High Risk Services
Localized Issues (expansion joints, bolting, etc.)
Component Issues
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Risk Based Program
• Data Collection
• Definition of Corrosion Segments
• Risk Assessment
• Inspection plan
• Program Maintenance
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Program
• Segment and Risk Priorities
• Walk downs
– Leaks/Exceptions (local issues)
– Hangers, Supports, Anchor inspections
– Specification issues
– As-built design
• Stress Analysis (if needed)
• Apply the Non Destructive Examination “Toolbox”
– Surface Examinations
– Volumetric Examinations
– Metallurgical Examinations
– Screening Technologies
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INSPECTION
PLAN
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Program Maintenance
• Maintain
specifications
• Document
• Failure Analysis
Program
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Contact Information
Joe Maciejczyk, PE
Associate
Structural Integrity Associates
Cell: 804-502-2820
www.structint.com