Superheater Outlet Header: Validation of Fitness for Service Methodologies

Header that burst during service

This project will conduct a Root Cause Analysis (RCA) for an ex-service header which, based on previous inspection, has been retired due to the extent of damage present.

The project will investigate the link between operation, materials properties, NDE and damage, and provide valuable feedback for options to minimize damage on similar components.

An RCA is part of EPRI’s recommended strategy for life management of high energy components. The RCA establishes the factors affecting damage. In selected situations, it is appropriate to extend this engineering assessment to consider how the damage present in the component could propagate, and the resultant outcome. Within the power generation industry, failure outcomes are typically considered as either “leak type” (relatively slow release of pressure) or “break type” (relatively fast release of pressure). These different failure outcomes have very important implications for safety and remediation.

  • Demonstration of a Root Cause Analysis and Condition Assessment linked to fitness for service
  • Unique opportunity for validation of fitness for service assessment methodologies based on a component with known damage
  • Comparison of the results from in-service non-destructive examination with physical measurements
  • Establishes the basis for run/repair/replace decision-making based on analysis of the risk of burst type fracture

This project will involve research that is carried out in two phases; however, the initial commitment is for Phase 1. Decisions regarding the work and schedule for Phase 2 will be determined later by the project team based on the results from Phase 1.

  • Phase 1—Engineering Assessment and Analysis
  • Phase 2—Pressure Test

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