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dence can provide an indication, as does swelling. Welds (seam or girth) coinciding with tube penetrations are often the first areas of creep damage. On thicker headers, thermal creep-fatigue can be a factor. Top-to-bottom differentials can give rise to distinctively oriented cracking. Where creep damage is identified or suspected, removing samples and subjecting them to accelerated creep and rupture testing provides the strongest basis for determining remaining life. Testing overcomes the problem of the unknown initial creep strength, since the test directly measures the property of interest. Extracting a core sample, as though a tube penetration was required, is the easiest sampling technique to repair. Samples from the core are then fabricated into a test sample for creep and rupture testing.
As manufactured drawing (actual thickness) Plant maximum continuous rating (MCR) temperature and pressure DCS data showing operating pressure and steam temperature for steady and cyclic operation Nipple thermocouple data showing the side-side temperature variation and start up-shut down cycle temperatures. Inspection data confirming existence and position of seamwelds, OD and thickness measurements, UT of welds, on-site metallography Results of accelerated creep testing of samples
Header life is known to be comparable with or greater than minimum rupture life based on design stress and temperature. Inspection has uncovered evidence of reduced wall thickness, creep damage, cracking or swelling.
Estimation of remaining life of high temperature headers follows a number of possible paths depending on the available information. The following possibilities are based on the use of API-579/ASME-FFS mechanical properties data.
Inspection interval, inspection techniques Time to schedule replacements De-rating to reduce risks until next outage Temperature and strain monitoring
Remaining life based on design or operating data Prediction of swelling Probability of failure before the next inspection. Crack growth calculations and leak-before-break or fracture prediction
Due to the complexity of header remaining life predictions, leverage of plant experience and expertise is essential. SES will work closely with plant personnel to develop a comprehensive plan for header risk management.
Design drawing showing material, design dimensions, position of welds, design temperature and pressure