Successful inspection of critical stainless steel

pipeline using NDT techniques and Engineering

Critical Assessment
Case Study
TWI worked with a refinery operator to conduct a detailed inspection of a stainless steel pipeline
critical to the operations of the plant. The pipeline had experienced excessive temperature cycling
due to a valve malfunction within the piping loop.

Background
Plant operators face an increasingly complex challenge when managing the integrity of assets
achieving operational excellence and maximum asset performance while minimising costs and
maintaining the highest safety and environmental standards. To determine the correct approach to
achieve this, pipeline owners and operators must integrate and assess critical data from different
sources such as the pipeline route, materials, facilities, operations, inspections, repairs and
modifications.
Through the application of detailed knowledge of materials degradation processes, inspection and
structural integrity, TWI has a demonstrable track record in assisting members with such aims.
The project carried out by TWI on behalf of the client comprised:

planning and selection of appropriate inspection techniques

inspection activities
assessment of inspection results.

Planning and selection of appropriate inspection techniques

In order to correctly identify the appropriate inspection techniques, TWI first reviewed the historical
operational data for the piping loop which had experienced high levels of thermal cycling. From this
data TWI asset integrity engineers identified a number of possible damage mechanisms which may
have affected the integrity performance of the pipe where it had undergone low temperature
excursions. These ranged from a possible reduction in toughness and external pitting to cracking
resulting from fatigue or external stress corrosion cracking (SCC).
[ Zoom ]

TWI was able to identify the possible locations of such damage and recommend appropriate
inspection methods for their detection (see Table).

Inspection activities
For those NDT methods identified within the table, TWI carried out the following tasks:

established outline NDT techniques based upon knowledge of flaw morphology and prior
experience
developed appropriate calibration pieces to support the NDT techniques to be deployed

finalised the efficacy of the techniques via trials and modelling as appropriate, and modified
the techniques as required

established written NDT procedures.

Following approval and demonstration of these procedures:

mobilised necessary tools and suitably qualified inspection personnel to carry out NDT on-site
issued comprehensive reports on NDT findings.

Assessment of inspection results

Our proposed scope of work to the client also included carrying out an Engineering Critical
Assessment (ECA) to determine the critical tolerable flaw size, against which any crack-like flaws
detected could be assessed.
ECA is based upon fracture mechanics principles to determine whether or not a flaw of a specific size
will pose a risk of failure due to any combination of fatigue, brittle fracture and plastic collapse
during the design life of a structure or component.
There are three essential elements of ECA: geometry and size of component and flaw, material
properties (tensile and fracture toughness) and loading (cyclic and static stresses). The material
properties required for the ECA are obtained from a tensile and fracture mechanics testing
programme.

Possible
damage
mechanism

Cause

Effect

Inspection
method

Locations to
inspect

Compare
weldments
Low
(weld and HAZ)
Austenite to
temperature
Reduction Eddy current which have
martensite
upsets in 2009 in
or
experienced
transformation (down to
ductility
Ferritscope
upset and those
-100C)
which have not.
Focus at coldest
locations

External
chloride SCC

Operating
temperatures
exceeding
60C, in
coastal
environment,
no protective
coating

External
pitting

Operating in
coastal
environment,
no protective
coating

Fatigue

External
cracking

Liquid
penetrant
inspection
(PT), phased
array
ultrasonic
testing
(PAUT)

Weldments
(including
attachments),
bends, water
trap areas

Localised
metal
loss

Visual
inspection,
PT

Water trap
areas

Connected to
Fatigue
rotating
cracking
equipment and
thermal

PT, PAUT

Weldments
(including
attachments),
where pipe is

cycling

constrained, eg
supports, etc

Thermal shock

Fast thermal
cycling

Cracking

PT, PAUT

At and near
injection points,
weldments
(including
attachments),
where pipe is
constrained

Internal
erosion

Internal liquid
flow,
particulate
contaminants

Metal
thinning

Manual
ultrasonic
testing

Low points (6
o'clock
position), bends

For more information on TWIs work in this area please contact us.

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