ASME B31.

1 Operation and
Maintenance Requirements-From
a Code Perspective
2014 IDEA Campus Workshop
Monte K. Engelkemier, P.E.

Agenda

Organization of ASME B31.1

History of O&M
Goals of O&M
Condition Assessment
O&M Procedures
Records
A Common Pressure Failure Example: Banana
Effect

Organization of ASME B31.1 Committee

Main Committee*
Subgroups (Chapters & Appendices)

General Requirements (CH I & IV, APP F-J)

Design* (CH II, MA D, NMA II)
Materials (CH III, MA A-C, NMA V)
Fabrication & Examination (CH V & IV,
Operation & Maintenance* (CH VII, NMA V)
Special Assignments (Everything Else)
*Member
Personally involved with ASME B31.1 Since 2006; currently the
Design and O&M Secretary; Member of the New FRP Code

History of B31.1 O&M

Acknowledgement
Joe Frey, P.E., one of the
driving forces behind the
scenes to get the initial
version of Chapter VII
into the 2007 Edition of
Code. Current Chairman
of B31.1.

Two Papers on the Subject

EPRI 1018998 Guideline for Compliance to
B31.1 Chapter VII, Operation and
Maintenance
ASME PVP-26069 High-Energy Piping Systems
are Now Covered Piping Systems

Chapter VII Operation &

Maintenance
ASME B31.1 addresses the operation and
maintenance of power piping 2007 edition.
The inspection and evaluations methods are
acknowledged, but not detailed.
Wanted Owners to have a plan to address
O&M. It didnt need to be a great plan, but
something was better than nothing.

APPENDIX V

Predates Chapter VII

Added to B31.1 after Mohave Failure 6/9/85
Nonmandatory
How to maintain critical piping
Where details of condition assessment are
introduced into the Code
Overtime portions of Appendix V are being
merged into Chapter VII

The W. A. Parish 8 CR Seam Weld Failure

Prompted Two Industry Reactions:
1. Seal welded cold reheat systems were added
to the inspection programs fatigue cracks
2. ASME B31.1 Code Committee renewed
efforts on Appendix V and then began work
on a new mandatory operation and
maintenance chapter. Chapter VII was
published in December of 2007.

Other ASME Codes with

O&M Requirements
B31.4 2002 Pipeline Transportation Systems
For Liquid Hydrocarbons and Other Liquids
(Chapter VII)
B31.8 2003 Gas Transmission And Distribution
Systems (Chapter V)
B31.11 2002 Slurry Transportation Piping
Systems (Chapter VII)
High Pressure System HPS 2003 (Section 5000)

Goals of B31.1 O&M

Thou Shall
Know the Condition of
Thy Condition
-Piping Gods (Before We Knew it was Round
with a Hole)

GENERAL
Managing safe pipe service begins with the
initial project concept and continues
throughout the service life of the system.
Any new failure reinforces this protocol.

OPERATION AND MAINTENANCE

PROCEDURES
The Operating Company shall be responsible
for the safe operation and maintenance of
their power piping.

Covered piping systems (CPS): Piping

systems on which condition assessments
are to be conducted:
NPS 4 and larger MS, HRH, CRH, &
BFW
NPS 4 and larger in other systems that
operate above 750F or above 1025 psi.
The Operating Company may, in its
judgment, include other piping
systems determined to be hazardous
by an engineering evaluation of
probability and consequences of
failure.

Condition Assessment

CONDITION ASSESSMENT
OF CPS
A condition assessment shall be performed
periodically based on condition.
What is a good period?
3 Years
5 Years
10 Years

Basis for determining extent of

assessment and re-inspection
interval
Consideration of the age of the CPS, the
previous documented condition, anticipated
operating conditions.
This includes remaining life assessment.

O&M Procedures

OPERATION AND MAINTENANCE

PROCEDURES (Who is Doing This?)

Operation of piping system within design limits

Documentation of system operating hours and
hot, warm, and cold starts
Documentation of actual operating
temperatures and pressures
Documentation of system excursions including
pipe hammers
Documentation of modifications and repairs to
CPS
Document hydro pinning requirements

OPERATION AND MAINTENANCE

PROCEDURES
Maintenance of pipe supports
Maintenance of piping system vents, drains, and
relief valves
Maintenance of steam attemperators
Assessment of deteriorating mechanisms
including; creep, fatigue, corrosion, erosion
Documentation of condition of CPS
Maintenance of CPS

Records

RECORDS
The condition assessment reports and any
reference documents, such as procedures
required by para. 139, drawings and reports,
shall be maintained and accessible for the life
of the plant.

RECORDS

System name
Material specification
Design temperature and pressure
Operating temperature and pressure
Design diameter and wall thickness
Operating hours, both total and since last
annual report
Hot, warm, and cold starts, both total and since
last annual report

RECORDS

Pipe support hot and cold walk down readings and

conditions, both past and current
List of CPS dynamic events including hammers and
slugs.
Hydro test pinning requirements
Modifications and repairs
Summary of pipe system inspection findings,
including list of areas of concern
Recommendations for re-inspection interval and
scope

RECORDS (recommended)

Actual pipe wall thickness and OD

Fabrication and erection welding information
such as material, process, and PWHT used.
Fabrication Repair history
Final Weld Adjustments Actual Measurements
i.e. Cold Pull

Failures Driving O&M

Utility

Plant/Unit

Date

Structure

Time in

Type of Failure

Service
Gulf States

Sabine

Utilities

Unit 1

So. Cal.

Mohave

Edison

Unit 2

Detroit Edison

Monroe

1979

HRH bend

120,000 hrs

Catastrophic
(creep)

1985

HRH horiz.
spool

88,000 hrs

Catastrophic
(creep)

1986

HRH horiz.
spool

97,000 hrs

Catastrophic
(creep)

13 years

Catastrophic
(FAC)

212,000 hrs

Through-wall
leak (creep)

156,000 hrs

Through-wall
leak (creep)

150,000 hrs

Catastrophic
(fatigue)

Unit 1

Virginia Pwr

Surry Unit 2

1986

BF Elbow

Gulf States Utilities

Sabine

1992

HRH bend

1992

SH Link

1993

CRH horz
Bend

Unit 2
Alabama Pwr (Southern
Co)

Gaston

Tampa Electric

Gannon

Unit 5
Unit 6

Utility

Plant/Unit

Date

Structure

Time in

Type of Failure

Service
Wisconsin Electric

Pleasant Prairie
Unit 1

1995

BF tee branch

East Kentucky
Power

Spurlock Unit 2

1996

SH Link

Virginia Power

Mt. Storm Unit

1

1996

SH Link

Kansas City

1998

SH Link

P& L

Hawthorne
Unit 5

Texas Genco

W A Parish

2003

CRH horiz
spool

2004

FW before

~125,000 hrs

Unit 8
Kansai Elec Pwr
Co

Mihama
Unit 3

Kansas City
P& L

15 years

Iatan

2007

Catastrophic
(FAC)
Through-wall
leak (creep)

~200,000 hrs

Catastrophic
(creep)

~225,000 hrs

Catastrophic
(creep)

145,000 hrs

Catastrophic
(fatigue)

185000 hrs

Catastrophic

D/a

(FAC)

Desuperheater
piping

Catastrophic
(FAC)

27 years

Desuperheater Supply Piping Failure

Failure occurred between gate valve & elbow
**THIS IS NOT A CONTROL VALVE, IT IS OPEN OR CLOSED**
Before

After

A Common Pressure Failure Example:

Banana Effect
What happens when a Desuperheater is
used too much?

Piping Layout
Paper Mill
Anchor

Flow
Element
Anchor

Steam
Source and
DSH to 150
PSIG
Saturated

Short Distance before

first elbow

Internals
ended up in
a Paper Mill
Strainer
Basket

Grout busted loose

from the water
hammer

Notice Crack in soil

around pier. The
crack was observed
to be about 1 to 2
inches wide

Thermal Gradient

LHot (Toperating)
During Operation

LCold (Toperating)
LCold = LHot at Toperating
During Shutdown

LCold LHot at 70 F

The Big Effect

Piping not uniformly heated causing:
Supports to lift off
Permanent Deformation of the Piping
Almost killing workers

Spring
Topped Off

Support lifts up so lets shim it! Not

once, not twice, but three or four
times.

Lets shim here too.

Flow Element popped up

~24, shearing the last bolts.
Eventually coming to rest 8
above intended elevation.

Notice the sledge

hammer.

There was one worker on

either side of the pipe, if
pipe goes left or right
theyre dead.

Recommendations
Better control of DSH
Return supports to their original design
Bolt-up new Flanged Element in a stress free
state, cut and miter existing 45 run to
accomplish this
Perform NDE to determine if the whole system
should be replaced in a future shutdown
Reevaluate System Drains

How it was Fixed

Spring Cans were returned to
their original setting, shims were
used to take-up the gap.
The 45 degree section shown,
was cut and mitered to take up
the offset caused. (ONE TIME FIX)
Next time, replace the system.

Thank-you!
Questions???
Contact Information:
Monte K. Engelkemier, P.E.
engelkemierm@stanleygroup.com
563-264-6641 work