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ACME Chemicals

Houston, TX

Report No.: N-24HS-PIPING


Inspector: Jeff Walling
Employer: Eagle Inspection
Inspection Date: 7/12/2010

IN-SERVICE
Inspection Report For

High Pressure Steam (HS) Piping


System ID: 36
Building 24
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 accordance
with 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.

Inspector Signature
API Certification No. 341
Report No.: N-24HS-PIPING

Page 1

TABLE OF CONTENTS
1.0 EXECUTIVE SUMMARY
2.0 VESSEL DATA
3.0 INSPECTION RESULTS
3.1 Leaks
3.2 Misalignment
3.3 Vibration
3.4 Support
3.5 Corrosion
3.6 Insulation
3.7 Other
4.0 RECOMMENDATIONS
4.1 Leaks
4.2 Misalignment
4.3 Vibration
4.4 Support
4.5 Corrosion
4.6 Insulation
4.7 Other
5.0 ULTRASONIC THICKNESS MEASUREMENTS
5.1 Results
5.2 Recommendations
APPENDICIES

APPENDIX A

Mechancial Integrity Calculations

APPENDIX B

Thickness Measurement Record

APPENDIX C

API 570 Inspection Checklist

APPENDIX D

Inspection Drawings

APPENDIX E

Inspection Photographs

APPENDIX F

NDE Reports

APPENDIX G

P&ID's

Report No.: N-24HS-PIPING

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:
Next Visual inspection is due by:

7/13/2015

Next UT inspection is due by:

7/11/2020

Governing component limiting life:

034

Report No.: N-24HS-PIPING

Page 3

2.0 PIPING DATA

Service:

High Pressure Steam (HS) Piping

Circuit:

System ID: 36

Inspection Date:

7/12/2010

Build Date: (yr)

1960

Const Code:

ASME B31.1

Pipe Spec:

NA

Diameter (in.):

10", 6" & 3" Mains

Sup. Span (ft.):

20

Material Type:

Ferritic Steels

Flange Rating:

600

MAWP (psi):

520

Design Temp.: (F)

650

Oper. Press.: (psi)

450

Oper. Temp.: (F)

550

MDMT: (F)

-20

API Class:

Class 2

ASME Category:

Normal

Insulation Type:

Calcium Silicate (12.5lb ^3ft)

Insulation Thk.: (in) 3

Report No.: N-24HS-PIPING

Page 4

3.0 INSPECTION RESULTS


The following results are the summarization of a field checklist
that was utilized during the inspection of circuit System ID: 36
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.

3.4 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 300F
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

Report No.: N-24HS-PIPING

Page 5

4.0 RECOMMENDATIONS

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.

4.4 Supports:
4.4.1 None.

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

4.8 Next Inspection:


4.8.2 Next Visual inspection is due by

7/13/2015

4.8.3 Next UT inspection is due by

7/11/2020

4.8.4 Governing component limiting life

034

Report No.: N-24HS-PIPING

Page 6

5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS

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.

Report No.: N-24HS-PIPING

Page 7

APPENDIX A
Mechancial Integrity Calculations

1) Corrosion Rates
2) Remaining Life Calculations
3) Minimum Required Thickness Calculations
4) Structural Required Thickness Calculations

Report No.: N-24HS-PIPING

Page 8

API-570 PIPING EVALUATION


PIPE COMPONENT REMAINING LIFE
Report No

Client

Inspector

Circuit

Date

N-24HS-PIPING

ACME Chemical

Jeff Walling

System ID: 36

7/12/2010

Minimum Thickness Determinations:


a) The following pipe minimum thicknesses are based on the current inhouse engineering standards, which take into consideration, pressures,
structural integrity and localized corrosion allowance.
Size

<=2"

3"

4"

6"

8"

10"

12"

>12"

t min

0.100

0.100

0.100

0.100

0.125

0.125

0.156

0.156

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 Life Calculations:
CML

Line No.

001
002

24-HS-6-CS-B2-1
24-HS-6-CS-B3-1

003
004

Size Sch
6
6

80
80

24-HS-6-CS-B3-1

80

24-HS-6-CS-B3-1

80

005

24-HS-6-CS-B4-2

006

24-HS-6-CS-B4-2

007
008

Age

t prev t act t min

Ca

Cr

RL

0.432
0.432

0.454 0.143
0.304 0.143

0.311
0.161

0
0.00256

>20
63

50

0.432

0.281 0.143

0.138

0.00302

46

50

0.432

0.299 0.143

0.156

0.00266

59

80

50

0.432

0.438 0.143

0.295

>20

80

50

0.432

0.682 0.143

0.539

>20

24-HS-6-CS-B4-2
24-HS-6-CS-B4-2

6
6

80
80

50
50

0.432
0.432

0.428 0.143
0.301 0.143

0.285
0.158

8.0E-05
0.00262

>20
60

009

24-HS-6-CS-MSH-3

80

50

0.432

0.426 0.143

0.283

0.00012

2358

010

24-HS-10-CS-MSH-3

10

40

50

0.365

0.416 0.162

0.254

>20

011

24-HS-10-CS-MSH-3

10

40

50

0.365

0.403 0.162

0.241

>20

012
013

24-HS-10-CS-MSH-3
24-HS-10-CS-MSH-3

10
10

40
40

50
50

0.365
0.365

0.357 0.162
0.377 0.162

0.195
0.215

0.00016
0

1216
>20

014

24-HS-10-CS-MSH-3

10

40

50

0.365

0.321 0.162

0.159

0.00088

180

015

24-HS-10-CS-MSH-4

10

40

50

0.365

0.375 0.162

0.213

>20

016

24-HS-10-CS-MSH-4

10

40

50

0.365

0.367 0.162

0.205

>20

017

24-HS-10-CS-MSH-4

10

40

50

0.365

0.368 0.162

0.206

>20

018
019

24-HS-10-CS-MSH-4
24-HS-10-CS-MSH-4

10
10

40
40

50
50

0.365
0.365

0.462 0.162
0.261 0.162

0.300
0.099

0
0.00208

>20
47

020

24-HS-6-CS-BP-4

80

50

0.432

0.382 0.143

0.239

0.001

239

021

24-HS-10-CS-MSH-4

10

40

50

0.365

0.260 0.162

0.098

0.0021

46

022

24-HS-6-CS-MSH-4

80

50

0.432

0.424 0.143

0.281

0.00016

1756

023

24-HS-6-CS-MSH-4

80

50

0.432

0.424 0.143

0.281

0.00016

1756

Report No.:

50
50

N-24HS-PIPING

Page 9

Pipe Component Remaining Life Calculations:


CML

Line No.

024

24-HS-6-CS-MSH-4

025

Size Sch
6

80

24-HS-6-CS-BP-4

80

026

24-HS-6-CS-MSH-4

027

24-HS-6-CS-MSH-4

028

24-HS-6-CS-MSH-4

029
030

Age

t prev t act t min

Ca

Cr

RL

0.432

0.404 0.143

0.261

0.00056

466

50

0.432

0.377 0.143

0.234

0.0011

213

80

50

0.432

0.403 0.143

0.260

0.00058

448

80

50

0.432

0.413 0.143

0.270

0.00038

711

80

50

0.432

0.282 0.143

0.139

0.003

46

24-HS-6-CS-MSH-4
24-HS-3-CS-C3-4

6
3

80
80

50
50

0.432
0.300

0.396 0.143
0.223 0.158

0.253
0.065

0.00072
0.00154

351
42

031

24-HS-3-CS-C3-4

80

50

0.300

0.276 0.158

0.118

0.00048

246

032

24-HS-3-CS-C2-4

80

50

0.300

0.239 0.158

0.081

0.00122

66

033

24-HS-3-CS-C2-4

80

50

0.300

0.235 0.158

0.077

0.0013

59

034
035

24-HS-3-CS-C2-4
24-HS-3-CS-C1-4

3
3

80
80

50
50

0.300
0.300

0.211 0.158
0.240 0.158

0.053
0.082

0.00178
0.0012

30
68

036

24-HS-3-CS-C1-4

80

50

0.300

0.250 0.158

0.092

0.001

92

037

24-HS-6-CS-B5-2

80

50

0.432

0.495 0.143

0.352

>20

038

24-HS-6-CS-B5-2

80

50

0.432

0.478 0.143

0.335

>20

039

24-HS-6-CS-B5-2

80

50

0.432

0.540 0.143

0.397

>20

040
041

24-HS-6-CS-MSH-4
24-HS-10-CS-MSH-3

6
10

80
40

50
50

0.432
0.365

0.591 0.143
0.352 0.162

0.448
0.190

0
0.00026

>20
729

Report No.:

50

N-24HS-PIPING

Page 10

PIPE COMPONENT PRESSURE CALCULATIONS

Date
7/14/2010

ASME B31.1 104.1

Client:$&0(&KHPLFDO
Circuit

Project No.:
Line No. 24-6-HS-CS-BP

36

24HS-PIPING
Material

A 106

MAWP

S.H.

Prod. SG

Temp.

Size

Sch

tnom

Ca

520

0.01

650

80

0.432

0.331

Internal Pressure Minimum Thickness Calcs


Y
520.0 Design Pressure, psi
P
D

6.625

PD/2(SE+PY) = t
0.40 Coefficient

Outside Diameter, in.

17000 Stress, psi

Joint Efficiency

0.100

Minimum Thickness, in.

External Pressure Minimum Thickness Calculations


L

Effective Length, in.

Do

Outside Diameter, in.

L/Do

X-Chart

Do/t

Factor from Figure G


Stress Value

Pa

External Pressure, psi

Minimum Thickness, in.

Internal Pressure Calculations


t = tnom - Ca =

2SEt/D-2tY = P

0.101 Thickness, in.

524.7

External Pressure Calculations


t
L/Do
Do/t

4B/3(Do/t) = Pa
A

Thickness, in.
X-Chart

External Pressure, psi


Cylinder Capacities

lb's of Prod lb's of


Cu Ft Gals Water S.G. Prod.
4.525 33.9 282.21 0.01
2.8

Plate Data
Metal Material Catagory
Sq Ft Cu in CS/Crom. Stl
40.57 2521.5 0.2833 lbs/cu in

Project No.: 24HS-PIPING

Stress Value

Pa

2.881 Shell Radius, in.


0.432 Shell Thickness, in

5836.8

Factor from Figure G

Variables for Capacities


300 Shell Length, in.

Sq In

Internal Pressure, psi

Author: JLW

Page 11

Total lb's
lb's of
Steel
714.3

Prod + Steel
717
Page 1 of 3

Circuit

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

36

Material

A 106

MAWP

S.H.

Prod. SG

Temp.

Size

Sch

tnom

Ca

520

0.01

650

80

0.300

0.200

Internal Pressure Minimum Thickness Calcs

PD/2(SE+PY) = t
0.40 Coefficient

520.0

Design Pressure, psi

3.5

Outside Diameter, in.

17000 Stress, psi

Joint Efficiency

0.053

Minimum Thickness, in.

External Pressure Minimum Thickness Calculations


L

Effective Length, in.

Do

Outside Diameter, in.

L/Do

X-Chart

Do/t

Factor from Figure G


Stress Value

Pa

External Pressure, psi

Minimum Thickness, in.

Internal Pressure Calculations


t = tnom - Ca =

2SEt/D-2tY = P

0.100 Thickness, in.

994.2

External Pressure Calculations


t
L/Do
Do/t

4B/3(Do/t) = Pa
A

Thickness, in.
X-Chart

External Pressure, psi


Cylinder Capacities

lb's of Prod lb's of


Cu Ft Gals Water S.G. Prod.
1.147 8.58 71.511 0.01
0.7

Plate Data
Metal Material Catagory
Sq Ft Cu in CS/Crom. Stl
20.96 904.78 0.2833 lbs/cu in

Project No.: 24HS-PIPING

Stress Value

Pa

0.300 Shell Thickness, in

3015.9

Factor from Figure G

Variables for Capacities


300 Shell Length, in.
1.45 Shell Radius, in.

Sq In

Internal Pressure, psi

Author: JLW

Page 12

Total lb's
lb's of
Steel
256.3

Prod + Steel
257

Page 2 of 3

Circuit

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

36

A 106

MAWP

S.H.

Prod. SG

Temp.

Size

Sch

tnom

Ca

520

0.01

650

10

40

0.365

0.202

Internal Pressure Minimum Thickness Calcs

PD/2(SE+PY) = t
0.40 Coefficient

520.0

Design Pressure, psi

10.75

Outside Diameter, in.

17000 Stress, psi

Joint Efficiency

0.162

Minimum Thickness, in.

External Pressure Minimum Thickness Calculations


L

Effective Length, in.

Do

Outside Diameter, in.

L/Do

X-Chart

Do/t

Factor from Figure G


Stress Value

Pa

External Pressure, psi

Minimum Thickness, in.

Internal Pressure Calculations


t = tnom - Ca =

2SEt/D-2tY = P

0.163 Thickness, in.

521.9

External Pressure Calculations


t
L/Do
Do/t

4B/3(Do/t) = Pa
A

Thickness, in.
X-Chart

External Pressure, psi


Cylinder Capacities

lb's of Prod lb's of


Cu Ft Gals Water S.G. Prod.
13.69 102 853.72 0.01
8.5

Plate Data
Metal Material Catagory
Sq Ft Cu in CS/Crom. Stl
68.02 3572.5 0.2833 lbs/cu in

Project No.: 24HS-PIPING

Stress Value

Pa

0.365 Shell Thickness, in

9787.6

Factor from Figure G

Variables for Capacities


300 Shell Length, in.
5.01 Shell Radius, in.

Sq In

Internal Pressure, psi

Author: JLW

Page 13

Total lb's
lb's of
Steel
1012.1

Prod + Steel
1021

Page 3 of 3

Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010


Material
A 106

Company, Line#
ACME Chemical, 24-6-HS-CS

Temp.F Size
650
6

OD

Sch

t nom

6.625 0.432

80

Flange Weight

81

Lbs

Quantity

Total Flange Weight

162.0

Valve Weight

720

Lbs

Quantity

Total Valve Weight

720.0

Insul.

Calcium Silicate

Tk

Other Load

3.00

in.

Wt.

7.13

Wt.

Quantity

Lb/Ft TIW
0

142.6
0.0

TOW

3.313

Outside Radius (in.)

r
SG

2.881
0.01

Inside Radius (in.)

W1

2.381

Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)

Superheated HP Steam

240
1025

Support Spacing (in.)

0.009

Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)

Ss
L

W2

17000
0.000

Material Sress (psi)

0S

ca

Material Catagory CS/Crom. Stl

Center Load (lbs)

Mo1

61476

Mo2

78688
0.143

Corrosion allowance (in.)

Wm 0.2833

lbs/cu in

Load Bending Moment (in.-lbs) (Ss*L)/4)


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

Pipe hanger load evaluation (ASTM A36 or A575)


Valves

Flanges

Other Wt

Ins. Wt

Total Load

285.2

285.2

Rs 0.50

Rod Sizes (Dia.)

Rn 2

Number of Rods/Pipe Support

ML 1130

Supported Length
Da

Tw

1031

Total Support Load (lbs)

SL

2260

Support Load Max (lbs)

46

Load/Rod

480

in.

% Stressed

Piping Support Sufficient

NOTES:

Project :

24HS-PIPING

Company, Line# ACME Chemical, 24-6-HS-CS

Page 14

Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010


Material
A 106

Company, Line#
ACME Chemical, 24-3-HS-CS

Temp.F Size
650
3

Sch

OD

t nom

80

3.5

0.300

Flange Weight

23

Lbs

Quantity

Total Flange Weight

46.0

Valve Weight

170

Lbs

Quantity

Total Valve Weight

170.0

Insul.

Calcium Silicate

Tk

Other Load

2.00

in.

Wt.

2.84

Wt.

Quantity

Lb/Ft TIW

56.8

0.0

TOW

1.750

Outside Radius (in.)

r
SG

1.450
0.01

Inside Radius (in.)

W1

0.854

Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)

Superheated HP Steam

240
273

0.002

Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)

Ss
L

W2

0S

ca

Material Catagory CS/Crom. Stl

Support Spacing (in.)


Center Load (lbs)

17000
0.000

Material Sress (psi)

Mo1

16368

Mo2

22537
0.158

Corrosion allowance (in.)

Wm 0.2833

lbs/cu in

Load Bending Moment (in.-lbs) (Ss*L)/4)


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

Pipe hanger load evaluation (ASTM A36 or A575)


Valves

Flanges

Other Wt

Ins. Wt

Total Load

113.6

329.6

Rs 0.375
Rn 2
ML 610

Rod Sizes (Dia.)


Number of Rods/Pipe Support

Tw

597

SL

1220
49

Load/Rod

Supported Length
Da

480

in.

Total Support Load (lbs)


Support Load Max (lbs)
% Stressed

Piping Support Sufficient

NOTES:

Project :

24HS-PIPING

Company, Line# ACME Chemical, 24-3-HS-CS

Page 15

Pipe Structural Support Evaluation Project : 24HS-PIPING Date: 7/14/2010


Material
A 106

Company, Line#
ACME Chemical, 24-10-HS-CS

Temp.F Size
650
10

Flange Weight

190

Lbs

Quantity

Valve Weight

1880

Lbs

Quantity

Insul.

Calcium Silicate

Tk

Other Load

3.00

in.

Wt.

OD

Sch

t nom

10.75 0.365

40

Total Flange Weight

380.0

Total Valve Weight 1880.0


10.5

Wt.

Quantity

Lb/Ft TIW
0

210.0
0.0

TOW

5.375

Outside Radius (in.)

r
SG

5.010
0.01

Inside Radius (in.)

W1

3.374

Pipe Weight (lbs/in.) ([R^2]-[r^2]*Pi*Wm)

Superheated HP Steam

240
2470

Support Spacing (in.)

0.028

Fluid Weight (lbs/in.) (Pi*r^2*SG*0.03613)

Ss
L

W2
Mo1

148200

17000
0.000

Material Sress (psi)

Mo2

172695

0.116

0S

ca

Material Catagory CS/Crom. Stl

Center Load (lbs)

Corrosion allowance (in.)

Wm 0.2833

lbs/cu in

Load Bending Moment (in.-lbs) (Ss*L)/4)


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

Pipe hanger load evaluation (ASTM A36 or A575)


Valves

Flanges

Other Wt

Ins. Wt

Total Load

420

420

Rs 0.50

Rod Sizes (Dia.)

Rn 2

Number of Rods/Pipe Support

ML 1130

Supported Length
Da

Tw

1481

Total Support Load (lbs)

SL

2260

Support Load Max (lbs)

66

Load/Rod

480

in.

% Stressed

Piping Support Sufficient

NOTES:

Project :

24HS-PIPING

Company, Line# ACME Chemical, 24-10-HS-CS

Page 16

APPENDIX B
Thickness Measurement Record

Report No.: N-24HS-PIPING

Page 17

API-570 PIPING EVALUATION


Piping Inspection Data
Report No
N-24HS-PIPING

Client
ACME Chem.

Inspector

Circuit

Date

Jeff Walling

Circuit 36

7/12/2010

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)

CML #

Line No.

Size

Comp. Disc

001

24-HS-6-CS-B2-1

Elbow 45

0.454

0.454

002

24-HS-6-CS-B3-1

Elbow 90

0.304

0.304

003

24-HS-6-CS-B3-1

Elbow 90

0.281

0.281

004

24-HS-6-CS-B3-1

Elbow 90

0.299

0.299

005

24-HS-6-CS-B4-2

Elbow 90

0.438

0.438

006

24-HS-6-CS-B4-2

Elbow 90

0.682

0.682

007

24-HS-6-CS-B4-2

Straight Pipe

0.428

008

24-HS-6-CS-B4-2

Elbow 90

0.301

0.301

009

24-HS-6-CS-MSH-3

Straight Pipe

0.426

0.426

010

24-HS-10-CS-MSH-3

10

Elbow 90

0.416

0.416

011

24-HS-10-CS-MSH-3

10

Elbow 90

0.403

0.403

012

24-HS-10-CS-MSH-3

10

Elbow 90

0.357

0.357

013

24-HS-10-CS-MSH-3

10

Tee Fitting

0.377

0.377

014

24-HS-10-CS-MSH-3

10

Straight Pipe

0.321 0.338 0.357

0.321

015

24-HS-10-CS-MSH-4

10

Straight Pipe

016

24-HS-10-CS-MSH-4

10

Straight Pipe

0.367

0.367

017

24-HS-10-CS-MSH-4

10

Straight Pipe

0.368

0.368

018

24-HS-10-CS-MSH-4

10

Straight Pipe

0.462

0.462

019

24-HS-10-CS-MSH-4

10

Straight Pipe

0.261

0.261

020

24-HS-6-CS-BP-4

Elbow 90

0.382

0.382

021

24-HS-10-CS-MSH-4

10

Straight Pipe

0.260

0.260

Report No.: 24HS-PIPING

Page 18

tml-1 tml-2 tml-3 tml-4

0.462

0.413 0.375 0.400

t act

0.428

0.375

CML #

Line No.

Size

Comp. Disc

022

24-HS-6-CS-MSH-4

Elbow 90

0.424

0.424

023

24-HS-6-CS-MSH-4

Straight Pipe

0.424 0.431 0.437

0.424

024

24-HS-6-CS-MSH-4

Straight Pipe

0.450 0.445 0.404

0.404

025

24-HS-6-CS-BP-4

Elbow 90

0.377

0.377

026

24-HS-6-CS-MSH-4

Straight Pipe

027

24-HS-6-CS-MSH-4

Straight Pipe

0.432 0.431

028

24-HS-6-CS-MSH-4

Elbow 90

0.282

0.282

029

24-HS-6-CS-MSH-4

Elbow 90

0.396

0.396

030

24-HS-3-CS-C3-4

Elbow 90

0.223

0.223

031

24-HS-3-CS-C3-4

Straight Pipe

0.276

0.276

032

24-HS-3-CS-C2-4

Elbow 90

0.239

0.239

033

24-HS-3-CS-C2-4

Elbow 90

0.241 0.235 0.259

0.235

034

24-HS-3-CS-C2-4

Straight Pipe

0.211

0.211

035

24-HS-3-CS-C1-4

Elbow 90

0.240

0.240

036

24-HS-3-CS-C1-4

Straight Pipe

0.250

037

24-HS-6-CS-B5-2

Elbow 90

0.495

038

24-HS-6-CS-B5-2

Straight Pipe

039

24-HS-6-CS-B5-2

Elbow 90

0.540

0.540

040

24-HS-6-CS-MSH-4

Tee Fitting

0.591

0.591

041

24-HS-10-CS-MSH-3

10

Tee Fitting

0.352

0.352

Report No.: 24HS-PIPING

Page 19

tml-1 tml-2 tml-3 tml-4

t act

0.418 0.403

0.403

0.413

0.413

0.268 0.255

0.250
0.495

0.504 0.478

0.478

APPENDIX C
API 570 Inspection Checklist

Page 20

Report No.:

24HS-PIPING
ITEM

Company:
ACCEPTABLE

Iso No:

ACME Chemical
UNACCEPTABLE

Jeff Walling

Inspector:

API-570 PIPING INSPECTION CHECKLIST

Line No:
N/A

24-HS-3
24-HS-10-CS-MSH

Cert No.:
Date:

COMMENTS

LEAKS?

flange leak on manifold iso valve

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?

where visible, no sig. distortion or corrosion

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

minor spots

Missing jacketing/insulation

minor spots

Sealing deterioration
Bulging
Banding broken/missing

Notes:
Insulation 3" CalSil

Page 1 of 4
Page 21

0341
7/12/2010

Report No.:

24HS-PIPING

Company:

ITEM

ACCEPTABLE

Iso No:

ACME Chemical
UNACCEPTABLE

Jeff Walling

Inspector:

API-570 PIPING INSPECTION CHECKLIST

Line No:
N/A

24-HS-4
24-HS-10-CS-MSH

Cert No.:
Date:

COMMENTS

LEAKS?
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?

where visible, no sig. distortion or corrosion

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

minor spots

Missing jacketing/insulation

minor spots

Sealing deterioration
Bulging
Banding broken/missing

Notes:
Insulation 3" CalSil

Page 2 of 4
Page 22

0341
7/12/2010

Report No.:

24HS-PIPING

Company:

ITEM

ACCEPTABLE

Iso No:

ACME Chemical
UNACCEPTABLE

Jeff Walling

Inspector:

API-570 PIPING INSPECTION CHECKLIST

Line No:
N/A

24-HS-1
24-HS-6-CS-B2/3

Cert No.:
Date:

COMMENTS

LEAKS?
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?

where visible, no sig. distortion or corrosion

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

minor spots

Missing jacketing/insulation

minor spots

Sealing deterioration
Bulging
Banding broken/missing

Notes:
Insulation 3" CalSil

Page 3 of 4
Page 23

0341
7/12/2010

Report No.:

24HS-PIPING

Company:

ITEM

ACCEPTABLE

Iso No:

ACME Chemical
UNACCEPTABLE

Jeff Walling

Inspector:

API-570 PIPING INSPECTION CHECKLIST

Line No:
N/A

24-HS-2
24-HS-6-CS-B4/5

Cert No.:
Date:

COMMENTS

LEAKS?

valve stem leak on #4 boiler iso valve

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?

where visible, no sig. distortion or corrosion

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

minor spots

Missing jacketing/insulation

minor spots

Sealing deterioration
Bulging
Banding broken/missing

Notes:
Insulation 3" CalSil

Page 4 of 4
Page 24

0341
7/12/2010

APPENDIX D
Inspection Drawings

Report No.: NASA-24HS-PIPING

Page 25

Page 26

Page 27

Page 28

Page 29

APPENDIX E
Inspection Photographs

Report No.: NASA-24HS-PIPING

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

ACME CHEMICAL BLDG 24 HIGH PRESSURE STEAM (HS)


REPORT N-24HS-PIPING
INSPECTION PHOTOGRAPHS

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

Page 32

ACME CHEMICAL BLDG 24 HIGH PRESSURE STEAM (HS)


REPORT N-24HS-PIPING
INSPECTION PHOTOGRAPHS

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

Page 33

ACME CHEMICAL BLDG 24 HIGH PRESSURE STEAM (HS)


REPORT N-24HS-PIPING
INSPECTION PHOTOGRAPHS

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

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

Page 34

ACME CHEMICAL BLDG 24 HIGH PRESSURE STEAM (HS)


REPORT N-24HS-PIPING
INSPECTION PHOTOGRAPHS

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
NDE Reports

1) UT Calabration Report
2) NDE Technician Certification
3) API-570 Inspector Certification

Report No.: NASA-24HS-PIPING

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

Unit: Panameterics DL37+

Long Frq
SW Frq:

mHZ
mHZ

SW Frq:

mHZ

SW Frq:

mHZ

Size:
Size:
Size:
Size:

UT UNIT
S/N: 5904

Cal Date: 11/11/09

PROBE SPECIFICATIONS
.375
Type: D790
Type:
Type:
Type:

S/N 905216
S/N
S/N
S/N

COUPLANT
Surface Cond: Coated

MFG: Ultra Grade Gel-40

CALIBRATION STANDARD
Type: Raycheck 6 Step Block
S/N: 00-7235
Calibration Reference Level (db)
0: 51
45:
60:
Other:
0:
45:
60:

70:

Start Time: 0800

End Time:

End Time: 1200

Start Time:

Results/Comments: Reference API-570 Report

UT Level II Technician:

Jeff Walling

Page 37

70:

Jeffrey Walling

EAGLE I. TECHNOLOGIES

NAME:

NDT CERTIFICATION / QUALIFICATION RECORD

Employee ID Number:

NDT CERTIFICATIONS

EXAM SCORES

3965

METHOD

LEVEL

DATE

EXAMINER

GENERAL

SPECIFIC

PRACTICAL

COMPOSITE

EXPIRATION
DATE

RESTRICTIONS

UTT
PT
MT
MFE

II
II
II
II

4/9/2010
9/3/2010
9/3/2010
1/21/2011

Joe Monroe
Wayne Bailey
Wayne Bailey
Brian Rotto

86%
93%
93%
90%

100%
95%
95%
85%

95%
91%
85%
89%

94%
93%
91%
88%

4/9/2015
9/3/2015
9/3/2015
1/21/2016

thickness only
None
None
None

PREVIOUS EMPLOYER NDT CERTIFICATIONS


COMPANY NAME/ADDRESS

FROM

TO

NDT METHODS & HIGHEST LEVEL ATTAINED

CAPE
Westech Inspection
BP/GIANT
MATIS

6/2009
1/19/2004
9/1/1998
9/16/1995

9/2013
11/20/2009
4/15/2003
9/1/1998

Level II UTT/MT/PT/MFE
Level II UT thickness limited
Level II UTT/MT/PT/LT
Level II UTT/MT/PT

EYE EXAMINATION
DATE
TYPE
10/22/2012
Far
10/22/2012
Near
10/22/2012 Color Contrast

TESTED BY
Amer. Best
Amer. Best
Amer. Best

EDUCATION AND TRAINING


PASS / FAIL
Pass
Pass
Pass

refer to employee eye exam cert (CAPE-FRM-101)

OTHER NOTABLE CERTIFICATIONS OR


QUALIFICATIONS
CERT

EXP DATE

CERT

EXP DATE

API 653

4/30/2014

PD DEP

1/10/2016

API 510
API 570
STI

6/30/2014
6/30/2014
9/18/2017

NB Comm.
VA-B&PV Com
MET.AS

2014
2013
2012

Jeff Walling

NDE PROGRAM MANAGER

ASNT
CERT No.

SIGNATURE

10/22/2012
DATE

EIT Certification Record Form: CAPE-FRM-102

INSTRUCTOR

ORG

DATE

LENGTH

SUBJECT

David Spooner
David Spooner
Joe Monroe

MATIS

12/16/1997
12/16/1997
4/9/2010

12 hours
12 hours
24 hours

Level II UTT
Level II PT
Level II UTT

8/25/2010
8/27/2010
1/21/2011

20 hours
12 hours
8 hours

Level II MT
Level II PT
Level II MFE

Stan Meyer
Stan Meyer
Brian Rotto

MATIS
Eastern NDT
WCFS
WCFS
CAPE

TRAINEE / LEVEL I NDT HOURS (IF APPLICABLE)


METHOD

EMPLOYER

HOURS

TOTAL

DATE

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.
Page 38

Page 39

APPENDIX G
P&ID's

Report No.: N-24HS-PIPING

Page 40