News & View, Volume 48 | SI-FatiguePro Version 4.0 Crack Growth Module Application Case Study; Complex Multi-Cycle Nuclear Transients

News & Views, Volume 48 | SI:FatiguePro Version 4.0 Crack Growth Module – Application Case Study Complex Multi-Cycle Nuclear Transients

News & View, Volume 48 | SI-FatiguePro Version 4.0 Crack Growth Module Application Case Study; Complex Multi-Cycle Nuclear Transients

By: Curt Carney

As plants enter their initial or subsequent license renewal period one of the requirements is to show that fatigue (including environmental effects) is adequately managed.  For some locations in pressurized water reactors (PWRs), it can be difficult to demonstrate an environmental fatigue usage factor less than the code allowable value of 1.0.  Therefore, plants are increasingly turning to flaw tolerance evaluations using the rules of the ASME Code, Section XI, Appendix L.  Appendix L analytically determines an inspection interval based on the time it takes for a postulated flaw (axial or circumferential) to grow to the allowable flaw size.  For surge line locations, this evaluation can be very complex, as the crack growth assessment must consider many loadings, such as: insurge/outsurge effects, thermal stratification in the horizontal section of the line, thermal expansion of the piping (including anchor movements), and internal pressure.  Trying to envelope all of these loads using traditional tools can lead to excess conservatism in the evaluation, and short inspection intervals that reduce the value of an Appendix L evaluation.

News & Views, Volume 48 | Metallurgical Lab Case Study – Grade 91 Elbows Cracked Before Installation

By:  Wendy Weiss and Terry Totemeier

News & View, Volume 48 | Metallurgical Lab Case Study - Grade 91 Elbows Cracked Before InstallationStructural Integrity (SI) personnel visited a power plant construction site to examine four Grade 91 elbows (ASTM A234-WP91 20-inch OD Sch. 60) that were found to contain axially oriented surface indications. The elbows had not yet been installed. The indications were initially noticed during magnetic particle testing (MT) after one end of an elbow was field welded to a straight section and post weld heat treated (PWHT). Subsequently, three additional similarly welded elbows were inspected and indications were found at both the welded (inlet) and open (outlet) ends of three elbows. The elbow with the most significant indications was selected for SI’s on-site examinations. Figure 1 shows the inlet and outlet ends of the selected elbow.

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News & View, Volume 48 | Bypass Line Spray Issues

News & Views, Volume 48 | Bypass Line Spray Issues

News & View, Volume 48 | Bypass Line Spray IssuesBy:  Ben Ruchte and Kane Riggenbach

To provide operating flexibility, combined cycle plants are typically equipped with bypass systems (high pressure routing steam to cold reheat and hot reheat routing steam to the condenser).  These bypass systems include conditioning valves designed to reduce steam pressures followed by outlet desuperheaters which inject water to reduce steam temperatures.

This service environment exposes the downstream piping to a high frequency of temperature transients making these areas one of the most prominent ‘industry issues’.

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News & View, Volume 48 | Considerations of Pin Cracking in Finger Pin Turbine Blade Attachments

News & Views, Volume 48 | Considerations of Pin Cracking in Finger Pin Turbine Blade Attachments

By:  Cliff Lange and Matt Freeman

OEMs recommend periodic inspection of pinned finger turbine blade attachments for detection of service-induced damage as part of ongoing rotor maintenance activity. 

This article provides an example where ultrasonic inspection detected cracking in several pins of finger attachments and outlines an engineering assessment to support continued operation and identify a re-inspection interval.  This approach can be applied to other pinned finger blade attachments to determine suitability for service.

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News & View, Volume 48 | SI Field Service Quality and Efficiency Solutions

News & Views, Volume 48 | SI Field Service Quality and Efficiency Solutions

By:  Robert Chambers and Trey RippyNews & View, Volume 48 | SI Field Service Quality and Efficiency Solutions

To help meet demanding outage schedules and stay within lean operation and maintenance budgets, Structural Integrity Associates, Inc. (SI) has implemented several new field data collection and analysis tools that enable delivery of a higher-quality final inspection product in a more efficient manner. These include customized software tools for streamlining the NDE data acquisition, analysis, and reporting processes. Moving forward, these tools will reduce time-on-pipe for inspections, as well as the associated analysis and reporting time.

For large inspection scopes, collecting, tagging, managing, transferring, and documenting data can be a very labor-intensive process with opportunities for human performance errors. While inspection instruments and analysis software typically have built-in reporting capabilities, these tend to be very general so they can be applied to a wide variety of applications. This can make it cumbersome to tailor these features to a specific application.

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News & View, Volume 48 | Post Seismic Certification - What Do Manufacturers Do to Keep Their Products TRU Listed?

News & Views, Volume 48 | Post Seismic Certification: What Do Manufacturers Do to Keep Their Products TRU Listed?

By:  Galen Reid and Katie Braman How does TRU or the public know the manufacturer is continuing to produce a product that complies with the certified construction and configuration without retesting periodically? Certification of products to withstand extreme event loading can open many opportunities for manufacturers to sell high value products when others have a […]

News & View, Volume 48 | SI Supports Parsons' “DetectWise Modular COVID Test Facility

News & Views, Volume 48 | SI Supports Parsons’ “DetectWise” Modular COVID Test Facility

By:  Zach Withall and Matthew Naugle, PENews & View, Volume 48 | SI Supports Parsons' “DetectWise Modular COVID Test Facility

The health facility is designed to fully separate patients from medical workers, protecting both parties and minimizing the PPE required to operate the suite.

COVID-19 has presented humanity with unprecedented challenges.  As economies reopen, solutions are needed that allow businesses to operate while protecting the health, safety, and security of the general public.

In an effort to positively impact that change, Structural Integrity Associates (SI) is working with Parsons Corporation, a global technology leader, to design a self-contained, mobile health screening facility for rapid, efficient and scalable testing.

The mobile facility is part of Parsons’ DetectWise™ suite of health solutions meant to combat the COVID-19 pandemic. SI provided structural design services for the facility.

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News & View, Volume 48 | Implementation of Material Verification In Support of Mega-Rule Part 1 Requirements

News & Views, Volume 48 | Implementation of Material Verification – In Support of Mega-Rule Part 1 Requirements

By:  Roger Royer, Scott Riccardella, and David BabbittNews & View, Volume 48 | Implementation of Material Verification In Support of Mega-Rule Part 1 Requirements

Operators are now required to define sampling programs and perform destructive (laboratory) or non-destructive testing to capture this information and take additional actions when inconsistent results are identified until a confidence level of 95% is achieved.

Various sections of Mega-Rule 1 require operators of natural gas transmission pipelines to ensure adequate Traceable, Verifiable, and Complete (TV&C) material records or implement a Material Verification (MV) Program to confirm specific pipeline attributes including diameter, wall thickness, seam type, and grade. Operators are now required to define sampling programs and perform destructive (laboratory) or non-destructive testing to capture this information and take additional actions when inconsistent results are identified until a confidence level of 95% is achieved.  Opportunistic sampling per population is required until completion of testing of one excavation per mile (rounded up to the nearest whole number) up to 150 excavations (if the population exceeds 150 miles).  Regulators have communicated an expectation that sampling locations or test sites are to be equally spaced throughout the population mileage.

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News & View, Volume 48 | Strategic Evaluation of MAOP Reconfirmation Plans and Options

News & Views, Volume 48 | Strategic Evaluation of MAOP – Reconfirmation Plans and Options

By:  Scott Riccardella and Bruce PaskettNews & View, Volume 48 | Strategic Evaluation of MAOP Reconfirmation Plans and Options

On October 1, 2019, the Pipeline and Hazardous Materials Safety Administration (PHMSA) published amendments to 49 CFR Parts 191 and 192 in the Federal Register issuing the Pipeline Safety: Safety of Gas Transmission Pipelines:  MAOP Reconfirmation, Expansion of Assessment Requirements, and Other Related Amendments Final Rule  (Final Rule). 

The Final Rule requires that for on-shore steel transmission pipelines in an High Consequence Area (HCA), Class 3 or 4 location without  Traceable, Verifiable and Complete (TV&C) records for §192.619(a)(2) (pressure testing, including records required by §192.517(a)) ; or where the Maximum Allowable Operating Pressure (MAOP) was established based on the Grandfather Clause and the MAOP creates a stress ≥ 30% of the Specified Minimum Yield Strength (SMYS), an operator will need to reconfirm the MAOP in accordance with the provisions of §192.624. 

News & View, Volume 48 | Optimizing Cathodic Protection Commitments Aging Management Program (AMP XI.M42)

News & Views, Volume 48 | Optimizing Cathodic Protection Commitments Aging Management Program (AMP XI.M42)

By: Shane McManus and Mark JaegerNews & View, Volume 48 | Optimizing Cathodic Protection Commitments Aging Management Program (AMP XI.M42)

License renewal applications (LRAs) often involve commitments to future actions.  These can be classified into one of three categories: appropriate, overcommitment, and ambiguous implementation.  Appropriate commitments include those actions that are expected by the NRC (such as those explicitly identified in the GALL(1) and GALL-SLR(2)) as well as some less restrictive actions that are technically justified by engineering evaluation.  These commitments can generally be implemented within one operating cycle using existing technology, are cost-effective, and are consistent with the GALL and GALL-SLR.

Overcommitments and those commitments with ambiguous implementations can be avoided and cost-effectiveness optimized by obtaining independent third party reviews (ITPR) of the LRA.

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