Devt of Tube Repair Techniques For HR Steam Generators

Development of Tube Repair Techniques for Heat Recovery Steam Generators
Supporting Stress Analyses, Code Interpretation, and Internal Tube Repair

1010512
Effective December 6, 2006, this report has been made publicly available in accordance with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export Administration Regulations. As a result of this publication, this report is subject to only copyright protection and does not require any license agreement from EPRI. This notice supersedes the export control restrictions and any proprietary licensed material notices embedded in the document prior to publication.
Development of Tube Repair Techniques for Heat Recovery Steam Generators

Supporting Stress Analyses, Code Interpretation, and Internal Tube Repair
1010512
Technical Update, March 2006
EPRI Project Manager D. Gandy
ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1395 PO Box 10412, Palo Alto, California 94303-0813 USA 800.313.3774 650.855.2121 askepri@epri.com www.epri.com
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR (B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT. ORGANIZATION(S) THAT PREPARED THIS DOCUMENT Electric Power Research Institute (EPRI) Structural Integrity Associates
NOTE
For further information about EPRI, call the EPRI Customer Assistance Center at (800) 313-3774 or email askepri@epri.com Electric Power Research Institute and EPRI are registered service marks of the Electric Power Research Institute, Inc. Copyright 2006 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS
This report was prepared by Electric Power Research Institute (EPRI) NDE Center 1300 W.T. Harris Blvd. Charlotte, NC 28262 Principal Investigator D. Gandy Structural Integrity Associates 3500 Massillon Rd Suite 420 Uniontown, OH 44685 Principal Investigators E. Jones M. Berasi This report describes research sponsored by EPRI. The report is a corporate document that should be cited in the literature in the following manner: Development of Tube Repair Techniques for Heat Recovery Steam Generators: Supporting Stress Analyses, Code Interpretation, and Internal Tube Repair. EPRI, Palo Alto, CA: 2006. 1010512.
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PRODUCT DESCRIPTION
This report describes the results of two strategies for repair of heat recovery steam generators. The first few sections of this report provide supporting information for the tube-to-header attachment repair described in EPRI report 1010441. The remainder of the report describes a new repair strategy that is to get underway in early 2006 that looks to address tube repair from the inside diameter of a tube. Results and Findings The methodology and results of a finite element stress analyses performed on four configurations of Heat Recovery Steam Generator (HRSG) header-to-tube attachments is described herein. These analyses were performed to compare stress levels in the original method of attachment to those resulting from 3 alternative repair options designed to remove service-related cracking or other defects in the attachment weld. The repair options evaluated included two partial penetration welds and one full penetration weld. Stresses due to internal pressure and external tube bending loads were evaluated. For the two types of analysis completed in this study (internal pressure and unit bending moment), the original configuration generally showed higher stress levels than those found in the repair options. The full penetration repair weld option had the lowest stress levels. Challenges and Objectives This analysis (and the complete EPRI study on this matter) is important to all HRSG plant operators as headers in these units have shown a propensity for failure at the header-to-tube attachment weld during service. Furthermore, limited access typically associated with these headers generally precludes the use of traditional weld repairs made from the external surface of the header. As a result, EPRI has developed an innovative repair method performed from the inside of the header. The stress analysis of this report was subsequently important to demonstrate that this repair weld geometry would not introduce operating stresses greater than those of the original geometry. Applications, Values, and Use This analysis is one part of the ongoing EPRI study into repair options for HRSG header-to-tube weld.
EPRI Perspective This report provides the supporting stress analysis data for performing HRSG attachment repairs from the inside diameter of a header. Utilizing this information, along with the repair approach documented in EPRI Report 1010441, EPRI approached the National Board in early 2006 and gained acceptance of the new HRSG header-to-tube weld repair approach. With this in hand, utilities can now utilize the new repair approach to significantly reduce repair time when headerto-tube attachment cracking is identified. Furthermore, unnecessary removal and subsequent repair of undamaged tubes to gain access to the damaged attachment area can be eliminated altogether. Approach Using ANSYS 9.0 finite element software, a separate model for four different weld configurations was created and boundary conditions to simulate internal pressure and bending moment loads were applied. The results of this analysis were then presented to the National Board, along with a discussion of the overall header-to-tube attachment repair approach. Based on information, an Interpretation was provided by the National Board which enables utilities to now utilized the repair technology. Keywords HRSG header Stress analysis Stub tube attachment full penetration Partial penetration
vi
CONTENTS
1 INTRODUCTION ....................................................................................................................1-1 2 DESIGN INPUTS ....................................................................................................................2-1 Geometry ..............................................................................................................................2-1 Material Properties ................................................................................................................2-5 Loads ....................................................................................................................................2-5 Internal Pressure Boundary Conditions............................................................................2-5 Bending Moment Boundary Conditions ............................................................................2-5 3 RESULTS ...............................................................................................................................3-1 Internal Pressure Application Results ...................................................................................3-1 Bending Moment Application Results....................................................................................3-1 Conclusions and Recommendations.....................................................................................3-3 4 NATIONAL BOARD INTERPRETATION 04-15 ....................................................................4-5 5 INTERNAL TUBE REPAIR ....................................................................................................5-7 A APPENDIX ............................................................................................................................ A-1 Original Configuration Pressure Run Images....................................................................... A-1 Partial Penetration (0.225 Weld Depth) Pressure Run Images......................................... A-13 Partial Penetration (0.243 Weld Depth) Pressure Run Images......................................... A-25 Full Penetration Pressure Run Images .............................................................................. A-37 B APPENDIX ............................................................................................................................ B-1 Original Configuration Bending Moment Analysis Images ................................................... B-1 Partial Penetration (0.225 Weld Depth) Bending Moment Analysis Images ..................... B-15 Partial Penetration (0.243 Weld Depth) Bending Moment Analysis Images ..................... B-29 Full Penetration Bending Moment Analysis Images........................................................... B-43
vii
LIST OF FIGURES
Figure 2-1 Original Configuration 2-D Geometry (Side View) ....................................................2-2 Figure 2-2 Partial Penetration (0.243 Weld Depth) 2-D Geometry (Side View)........................2-3 Figure 2-3 Partial Penetration (0.225 Weld Depth) 2-D Geometry (Side View)........................2-4 Figure 2-4 View of Applied Pressure Loads...............................................................................2-6 Figure 2-5 View of Applied Forces for Bending Moment Analysis .............................................2-7 Figure 4-1 Interpretation 04-15 Part RD-2060 Utilizing a Flush Patch to Gain Access Window in Pressure Retaining Items. ......................................................................4-6 Figure A-1 Header Hoop Stress................................................................................................ A-1 Figure A-2 Header Hoop Stress................................................................................................ A-2 Figure A-3 Header Hoop Stress................................................................................................ A-3 Figure A-4 Header Axial Stress ................................................................................................ A-4 Figure A-5 Header Axial Stress ................................................................................................ A-5 Figure A-6 Header Axial Stress ................................................................................................ A-6 Figure A-7 1 Principal Stress................................................................................................... A-7 Figure A-8 1 Principal Stress................................................................................................... A-8 Figure A-9 1 Principal Stress................................................................................................... A-9 Figure A-10 Stress Intensity.................................................................................................... A-10 Figure A-11 Stress Intensity.................................................................................................... A-11 Figure A-12 Stress Intensity.................................................................................................... A-12 Figure A-13 Header Hoop Stress............................................................................................ A-13 Figure A-14 Header Hoop Stress............................................................................................ A-14 Figure A-15 Header Hoop Stress............................................................................................ A-15 Figure A-16 Header Axial Stress ............................................................................................ A-16 Figure A-17 Header Axial Stress ............................................................................................ A-17 Figure A-18 Header Axial Stress ............................................................................................ A-18 Figure A-19 1 Principal Stress............................................................................................... A-19 Figure A-20 1 Principal Stress............................................................................................... A-20 Figure A-21 1 Principal Stress............................................................................................... A-21 Figure A-22 Stress Intensity.................................................................................................... A-22 Figure A-23 Stress Intensity.................................................................................................... A-23 Figure A-24 Stress Intensity.................................................................................................... A-24 Figure A-25 Header Hoop Stress............................................................................................ A-25
st st st st st st
ix
Figure A-26 Header Hoop Stress............................................................................................ A-26 Figure A-27 Header Hoop Stress............................................................................................ A-27 Figure A-28 Header Axial Stress ............................................................................................ A-28 Figure A-29 Header Axial Stress ............................................................................................ A-29 Figure A-30 Header Axial Stress ............................................................................................ A-30 Figure A-31 1 Principal Stress............................................................................................... A-31 Figure A-32 1 Principal Stress............................................................................................... A-32 Figure A-33 1 Principal Stress............................................................................................... A-33 Figure A-34 Stress Intensity.................................................................................................... A-34 Figure A-35 Stress Intensity.................................................................................................... A-35 Figure A-36 Stress Intensity.................................................................................................... A-36 Figure A-37 Header Hoop Stress............................................................................................ A-37 Figure A-38 Header Hoop Stress............................................................................................ A-38 Figure A-39 Header Hoop Stress............................................................................................ A-39 Figure A-40 Header Axial Stress ............................................................................................ A-40 Figure A-41 Header Axial Stress ............................................................................................ A-41 Figure A-42 Header Axial Stress ............................................................................................ A-42 Figure A-43 1 Principal Stress............................................................................................... A-43 Figure A-44 1 Principal Stress............................................................................................... A-44 Figure A-45 1 Principal Stress............................................................................................... A-45 Figure A-46 Stress Intensity.................................................................................................... A-46 Figure A-47 Stress Intensity.................................................................................................... A-47 Figure A-48 Stress Intensity.................................................................................................... A-48 Figure B-1 Header Hoop Stress................................................................................................ B-1 Figure B-2 Header Hoop Stress................................................................................................ B-2 Figure B-3 Header Hoop Stress................................................................................................ B-3 Figure B-4 1 Principal Stress................................................................................................... B-4 Figure B-5 1 Principal Stress................................................................................................... B-5 Figure B-6 1 Principal Stress................................................................................................... B-6 Figure B-7 Stress Intensity........................................................................................................ B-7 Figure B-8 Stress Intensity........................................................................................................ B-8 Figure B-9 Stress Intensity........................................................................................................ B-9 Figure B-10 Tube Axial Stress ................................................................................................ B-10 Figure B-11 Tube Axial Stress ................................................................................................ B-11 Figure B-12 Tube Axial Stress ................................................................................................ B-12 Figure B-13 Tube Axial Stress ................................................................................................ B-13 Figure B-14 Tube Hoop Stress ............................................................................................... B-14 Figure B-15 Header Hoop Stress............................................................................................ B-15 Figure B-16 Header Hoop Stress............................................................................................ B-16
st st st st st st st st st
Figure B-17 Header Hoop Stres ............................................................................................. B-17 Figure B-18 1 Principal Stress............................................................................................... B-18 Figure B-19 1 Principal Stress............................................................................................... B-19 Figure B-20 1 Principal Stress............................................................................................... B-20 Figure B-21 Stress Intensity.................................................................................................... B-21 Figure B-22 Stress Intensity.................................................................................................... B-22 Figure B-23 Stress Intensity.................................................................................................... B-23 Figure B-24 Tube Axial Stress ................................................................................................ B-24 Figure B-25 Tube Axial Stress ................................................................................................ B-25 Figure B-26 Tube Axial Stress ................................................................................................ B-26 Figure B-27 Tube Axial Stress ................................................................................................ B-27 Figure B-28 Tube Hoop Stress ............................................................................................... B-28 Figure B-29 Header Hoop Stress............................................................................................ B-29 Figure B-30 Header Hoop Stress............................................................................................ B-30 Figure B-31 Header Hoop Stress............................................................................................ B-31 Figure B-32 1 Principal Stress............................................................................................... B-32 Figure B-33 1 Principal Stress............................................................................................... B-33 Figure B-34 1 Principal Stress............................................................................................... B-34 Figure B-35 Stress Intensity.................................................................................................... B-35 Figure B-36 Stress Intensity.................................................................................................... B-36 Figure B-37 Stress Intensity.................................................................................................... B-37 Figure B-38 Tube Axial Stress ................................................................................................ B-38 Figure B-39 Tube Axial Stress ................................................................................................ B-39 Figure B-40 Tube Axial Stress ................................................................................................ B-40 Figure B-41 Tube Axial Stress ................................................................................................ B-41 Figure B-42 Tube Hoop Stress ............................................................................................... B-42 Figure B-43 Header Hoop Stress............................................................................................ B-43 Figure B-44 Header Hoop Stress............................................................................................ B-44 Figure B-45 Header Hoop Stress............................................................................................ B-45 Figure B-46 1 Principal Stress .............................................................................................. B-46 Figure B-47 1 Principal Stress .............................................................................................. B-47 Figure B-48 1 Principal Stress .............................................................................................. B-48 Figure B-49 Stress Intensity.................................................................................................... B-49 Figure B-50 Stress Intensity.................................................................................................... B-50 Figure B-51 Stress Intensity.................................................................................................... B-51 Figure B-52 Tube Axial Stress ................................................................................................ B-52 Figure B-53 Tube Axial Stress ................................................................................................ B-53 Figure B-54 Tube Axial Stress ................................................................................................ B-54
ST ST ST st st st st st st
xi
xii
LIST OF TABLES
Table 2-1 Material Properties for P91 Material at 1000F..........................................................2-5 Table 3-1 Maximum and Minimum Stresses for Internal Pressure Analysis..............................3-2 Table 3-2 Maximum and Minimum Stresses for Bending Moment Analysis ..............................3-3
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1
INTRODUCTION
Plant owners have been experiencing failures in HRSG units where the tubes attach to the header. EPRI has been conducting research for different repair options at this attachment point including the use of a stub tube insert. Because this proposed fix will result in a much different geometry, stress analysis of the repair options was required to determine the resulting operating stresses relative to those existing in the original weld joint geometry. Finite element (FE) stress analysis was subsequently performed for one selected original header-to-tube weld joint geometry, and for three proposed repair configurations. The results of the analysis should show if significant additional stressing occurs in the repair methods. In order to compare the three different attachment configurations, two separate load conditions are analyzed. The first condition is internal pressure in the header. The second condition is an external tube bending moment that results from temperature differences that typically exist between adjacent tube legs entering the header. A specific bending moment was not determined for the evaluated header geometry. However, an equivalent unit bending moment was applied to each model to show the response of each configuration to this loading.
1-1
2
DESIGN INPUTS
Geometry
Four separate FE models were evaluated for this investigation, representing the original tube-toheader weld configuration, one full penetration weld repair, and two alternative partial penetration repairs. Figures 2-1 through 2-3 show 2-dimensional sketches of each geometry. Note that the two partial penetration configurations differ only with respect to the depth of the weld and corresponding depth of the un-fused area in the weld joint. It is also noted that because of the curvature of the header, the weld depth was held constant around the circumference of the tube. For the full penetration configuration, the weld depth is considered to be the full thickness of the header. The FE models for the pressure runs depict one-fourth of a tube cross-section and one-half of the header cross-section for one row of tubes. The models are restricted in the necessary planes so that further modeling of symmetrical sides of the header/tube is not necessary to apply the pressure loads and retrieve accurate results. For the bending moment analysis, however, it was necessary to mirror copy the model to create a full header cross-section and half cross-section of a tube. This change was necessary to correctly apply the forces that mimic a bending moment.
2-1
Design Inputs
Figure 2-1 Original Configuration 2-D Geometry (Side View)
2-2
Design Inputs
Figure 2-2 Partial Penetration (0.243 Weld Depth) 2-D Geometry (Side View)
2-3
Design Inputs
Figure 2-3 Partial Penetration (0.225 Weld Depth) 2-D Geometry (Side View)
2-4
Design Inputs
Material Properties
The material specified by EPRI for all three configurations is P91 (9Cr-Mo). The temperature was given as 1000F for the evaluated header. The material properties for P91 at 1000F are shown in Table 2-1.
Table 2-1 Material Properties for P91 Material at 1000F Property Elastic Modulus Secant Coefficient of Thermal Expansion Poisson's Ratio Density Value 25.4E+06 6.90E-06 0.3 0.277 lb/in3 Unit Psi in/in/oF
Loads
Internal Pressure Boundary Conditions The pressure stress run was made using an internal pressure of 1800 psi. This pressure was applied to the inner diameter of the tube and header. It should be noted that this pressure was also applied to all faces of the lack of weld fusion gap in the original configuration. Along with the internal pressure, an equivalent blow-off pressure was applied to the end of the tube and header cross-section opposite of the tube. Figure 2-4 shows the applied pressures for the original configuration. Bending Moment Boundary Conditions To simulate the effects of a bending moment, a force in the y-direction (tube axial direction) was placed on each node of the tube end face. The total sum of the absolute value of the nodal forces was 1000 in-lbs. It should be noted that one half of the modeled tube face was assigned positive forces and the other half was assigned equal but opposite forces to create a bending moment. Because no actual value was calculated for the magnitude of this moment, a unit value was assumed. This allows for easy comparison between the four configurations. Figure 2-5 shows the applied boundary condition for the bending moment run.
2-5
Design Inputs
Figure 2-4 View of Applied Pressure Loads
2-6
Design Inputs
Figure 2-5 View of Applied Forces for Bending Moment Analysis
2-7
3
RESULTS
Internal Pressure Application Results
A comparison of maximum and minimum stress values due to internal pressure application for each configuration can be seen in Table 3-1. Due to the geometry of the original design, it has the highest header hoop, header axial, and 1st principal stresses. It also has the highest stress intensity. All of these maximums for the original configuration are located at the end of the gap between the tube and header. Because this gap or lack of fusion is located so that it directly sees internal pressure (as opposed to the repair welds which have a gap on the outer diameter of the header), it makes sense that the pressure effects will cause high stress concentrations in this location. The actual stress concentration effect may be higher than that indicated in the FE results as this is dependent on mesh refinement of the FE model. The three repair configurations tested in this analysis show similar results for the pressure application. The full penetration repair option does have slightly lower stress values than the two partial repair configurations. Even though it doesnt directly see the effects of internal pressure, the lack of fusion created in the two partial penetration configurations does create enough of a concentration that its stresses are 2 to 17% higher than the full penetration design. Images that show the results of the internal pressure analysis for each configuration are available in Appendix A.
Bending Moment Application Results

The 1000 in-lbs bending moment maximum and minimum stress values and location of maximum stress are located in Table 3-2. As seen in this table, the stress values for the original configuration and partial penetration designs are very similar. The location of maximum stress for the original configuration is located at the top of the weld where it meets the tube outer diameter. For the partial penetration designs, the location is in the gap or lack of weld fusion area. This is to be expected because of the geometry of the weld and therefore the location of the lack of fusion. Similar to what is noted above for the pressure load, the actual stress concentration effect at this gap may not be completely captured in the FE results. The full penetration configuration shows significantly less stress than the original or repair designs. The stress intensity at the maximum location is over 40% less than the other options analyzed. This can be understood by realizing that the only stress riser is the sharp corner between the OD of the tube and the OD of the header. Since there is no lack of weld fusion associated with the full penetration geometry, this stress concentration is not present in this design Also, the original design has only the thickness of the original tube (0.180) at the location of highest stress as compared to the thickness of the stub tube (0.437) for the full 3-1
Results
penetration option. Images that show the results of the bending moment analysis for each configuration are available in Appendix B.
Table 3-1 Maximum and Minimum Stresses for Internal Pressure Analysis Pressure Stress Run Stress Comparison Header Attachment Welds Header hoop Original Configuration Header axial Principal INTENSITY Partial Penetration Repair (0.225" Weld Depth) Header hoop Header axial Principal INTENSITY Header hoop Header axial Principal INTENSITY Header hoop Full Penetration Repair Header axial Principal INTENSITY Maximum (ksi) 49.2 45.6 58.5 53.6 43.3 19.0 46.6 48.5 43.2 19.1 44.9 46.0 42.5 15.9 42.5 43.7 Minimum (ksi) -4.7 -8.8 1.4 3.7 -5.6 -2.5 0.0 0.4 -5.7 -3.1 0.0 0.4 -1.8 -1.8 0.1 0.4 Location
Weld Root at Tube OD (Gap End) Weld Root at Tube OD (Gap End) Weld Root at Tube OD (Gap End) Weld Root at Tube OD (Gap End) Tube ID at Header ID Gap End Gap End Gap End Tube ID at Header ID Gap End Gap End Gap End Tube ID at Header ID Intersection Header/Tube Tube ID at Header ID Tube ID at Header ID
Partial Penetration Repair (0.243" Weld Depth)
3-2
Results Table 3-2 Maximum and Minimum Stresses for Bending Moment Analysis Bending Moment Run Stress Comparison Header Attachment Welds Header hoop Original Configuration Tube axial Principal INTENSITY Partial Penetration Repair (0.225" Weld Depth) Header hoop Tube axial Principal INTENSITY Header hoop Tube axial Principal INTENSITY Header hoop Full Penetration Repair Tube axial Principal INTENSITY Maximum (ksi) 11.5 13.5 17.4 16.5 9.7 16.4 17.3 17.6 10.2 16.5 17.4 17.5 9.4 7.4 10.6 9.6 Minimum (ksi) -11.5 -13.5 -2.2 0.0 -9.7 -16.4 -4.2 0.0 -10.2 -16.5 -4.4 0.0 -9.4 -7.4 -1.6 0.0 Location (Max)
Top of Weld (Tube OD) Top of Weld (Tube OD) Top of Weld (Tube OD) Top of Weld (Tube OD) Gap End Gap End Gap End Gap End Gap End Gap End Gap End Gap End Intersection Header/Tube Intersection Header/Tube Intersection Header/Tube Intersection Header/Tube
Partial Penetration Repair (0.243" Weld Depth)
Conclusions and Recommendations

The results of the internal pressure and bending moment runs show similar results. For both, most of the applicable stresses are highest in the original configuration and lowest in the full penetration configuration. This is expected as the original configuration has a smaller tube thickness than the stub tube attachment used in the repair options and also a stress concentration associated with the lack of fusion on the internal surface. The especially high stresses seen in the original configuration during the internal pressure analysis give some potential insight into the failures seen by HRSG operators. The lack of fusion seems to create a significant stress concentration at the end of this gap and therefore could result in fatigue type cracking. The bending moment application showed no significantly higher stresses for this configuration over the two partial penetration designs, however. 3-3
Results
For the repair configurations in the pressure run, it should be noted that all three have very similar stress values. The full penetration design has the lowest stresses but the values are not significantly different that the two partial penetration options. In the bending moment analysis, however, the full penetration repair does show over 40% less first principal stress and stress intensity than the other three. After comparing the results of both the internal pressure and bending moment analyses for each configuration, evidence has been established that the replacement of the original header-to-tube attachment weld with any of the three repair options would reduce stresses for the two conditions analyzed in this project. The full penetration option, because it has no lack of fusion, has the lowest stress values of any of the configurations.
3-4
National Board Interpretation 04-15
4
NATIONAL BOARD INTERPRETATION 04-15
Following completion of a header-to-tube repair device described in EPRI Report 1010441, many member utilities asked that we work with ASME Boiler & Pressure Vessel Code and/or the National Board to make sure the new technology could be readily applied. Several discussions were held with ASME Section I members during the 4th quarter of 2005. It was recommended that we further discuss the approach with members of the National Board, since the new approach is considered at repair instead of new construction. National Board members were contacted in November 2005. The primary issue of discussion concentrated on whether the ID repair weld configuration was addressed by one of the configurations shown in ASME Section I PW-16. EPRI was asked to provide both an overview of the technology and supporting information (stress analysis data as reported earlier in this report) to NBIC in December. Subsequently, EPRI staff attended the January 2006 NBIC meeting to request an Interpretation on utilizing the new technology. The Interpretation 04-15 was titled: Part RD-2060 Utilizing a Flush Patch to Gain Access Window in Pressure Retaining Items. The official documentation for this is shown in Figure 4-1. With the Interpretation in hand, utilities should now be able to use the header-to-tube repair technology to address attachment cracking in the future.
4-5
National Board Interpretation 04-15
Figure 4-1
Interpretation 04-15 Part RD-2060 Utilizing a Flush Patch to Gain Access Window in Pressure Retaining Items.
4-6
Internal Tube Repair
5
INTERNAL TUBE REPAIR
Repair techniques for address two different types of HRSG repairs have been developed and reported in EPRI report 1010441. The techniques include repairs for tube-to-tube applications and for tube-to-header attachments. EPRI is continuing development in 2006 and has plans to develop an internal repair method for HRSG tubing. In December 2005, a request for proposal was sent out to 10 repair vendors/OEMs to initiate the process for developing the internal tube repair device. Proposals are expected by February 2006, and work should hopefully get underway by April 2006. The RFP is provided below:
Request For Proposal Internal Repair For HRSG & Boiler Tubing
Purpose of Work In recent years, flow accelerated corrosion (FAC) has become a significant problem for heat recovery steam generator (HRSG) tubing particularly at bends or locations where turbulence has increased. Damage can occur anywhere along the tube length and with time can result in tube leakage or blowout. Such failures are costly not only in terms of repair, but also in terms of lost availability of the plant. EPRI is currently developing inspection technologies that will enable power producers to examine tubes at various locations along the tube length. Assuming FAC damage can be located using this technology, an effective method to perform the repair is needed. The purpose of this Request for Proposal is to solicit proposals for the development of an Internal Welding Repair Device (IWRD) for HRSG and Boiler tubing which can be inserted from one end of the tube, transferred along the tube positioned at the exact location of the damage, and used to perform an ID weld buildup at that location. Statement of Work The Internal Welding Repair Device should make use of the gas tungsten arc welding (GTAW), gas metal arc welding (GMAW) or laser beam welding (LBW) process and should be capable of performing a weld buildup at a location along an HRSG tube or a boiler tube. The device should 5-7
be capable of insertion from within a header tube bore location allowing it to be pushed (from lower header) or dropped (from upper header) to the repair location. Access to the bore region can be accomplished by removal of an access port (hole) 180 degrees opposite the bore region of the header. Transfer along the tube inner diameter from below will require a certain rigidity (enabling the device to be pushed) or crawler capability to access the precise location of the repair. The IWRD should be capable of insertion and repair within tube diameters ranging from a 1.0 to 2.5 ID. Additionally, the repair device should be capable of navigating a bend angle of 25 degrees such as that shown in Figure 1. The tube-to-tube center spacing is 4.0 inches.
Figure 1. Example header configuration showing a tube bend angle of 25 degrees. The tube-to-tube spacing is 4.0 inches. The IWRD and welding system selected for the use should include: o A power supply o Automatic voltage control (AVC), if required. If GTAW is used, the bidder should propose the minimum diameter capability that can incorporate AVC, vision system, self centering device, etc. o A remote wire feed assembly or wire feed capabilities that can complete a single repair locations without re-insertion or wire reload o A weld head capable of operating in the 2G and 5G weld positions. 5-8
o A video probe vision system that provides real-time monitoring of the weld puddle. o A clamping device to center the IWRD at the precise repair location The RFP should address the following questions: o How will the tube ID be cleaned/machined/ground prior to welding? o How will the wire be fed to push it over a distance of 50-100ft? o What happens if the tungsten sticks during welding (GTAW process only)? What additional tooling would be required for rework if the tungsten should stick? o What diameter of wire will be used for the IWRD process? o What video probe vision system will be incorporated into the IWRD system. o How will the final surface be prepared to minimize flow disruptions within the tube which often lead to a second failure? A detailed specification stipulating surface roughness and buildup (reinforcement) will be required in final system. HRSG Tube Specifications o Tube ID 1.0 to 3.0 ID o Tube thickness > 0.125T o Distance IWRD must be inserted into tube to perform repairs: o If push/pull system, 0-50ft o If push only, 0-100ft o If pull only, 0-100ft. o Bend Angle (around dog leg) is 25 degreesSee Figure 1. o Tube spacing (center-to-center) is 4.0 inches. Period of Performance The period of performance will be April 2006 to December 2007. Several individual demonstrations of the IWRD systems capabilities will be required at specified intervals as shown in the Schedule below. Schedule & Demonstration EPRI will perform metallography and radiography to assess performance of the selected contractors ability to meet the following schedule and welding demonstrations. o Contractor will demonstrate ID tube welding capability on a 1 and 3 diameter tube at a distance of 5 feet from insertion of IWRD on a straight tube. (December 2006) o Contractor will demonstrate ID tube welding capability on a 1and 3 diameter tube at a distance of 50 feet from insertion of IWRD (April 2007) o Contractor will demonstrate ID tube welding capability on a 1 and 3 diameter tube with a radius as shown in Figure 1 at a distance of 50 feet from insertion of IWRD (August 2007) 5-9
o Contractor will demonstrate ID tube welding capability on a 1 and 3 diameter tube with a radius as shown in Figure 1 at a distance of 50 feet from insertion of IRD (December 2007) Successful demonstration of each of the above will be considered when the contractor meets both metallography and radiography requirements. Cost Information Cost-sharing of the IRWD development is encouraged. The proposal should include potential cost-sharing arrangements that apply to the bidder. Cost sharing will be considered for licensing agreements. EPRI will reward one contract; subcontracting is allowed, although the bidder will be responsible for subcontracted work. EPRI Project Manager David Gandy Commercialization Plan The bidder is to propose a commercialization plan. Evaluation Criteria See Attachment 1. List of Invitees a) b) c) d) e) f) g) h) i) j) Arc Machines, Inc Polyseude-Astro Arc Liburidi-Dimetrics Encompass Machines, Inc Magnatech Aggressive Equipment Welding Services, Inc. PCI Energy Areva GE Services
5-10
A
APPENDIX
Original Configuration Pressure Run Images
Figure A-1 Header Hoop Stress
A-1
Appendix
A-2
Appendix
A-3
Appendix
Figure A-4 Header Axial Stress
A-4
Appendix
A-5
Appendix
A-6
Appendix
Figure A-7 1st Principal Stress
A-7
Appendix
A-8
Appendix
A-9
Appendix
Figure A-10 Stress Intensity
A-10
Appendix
A-11
Appendix
A-12
Appendix
Partial Penetration (0.225 Weld Depth) Pressure Run Images
A-13
Appendix
A-14
Appendix
A-15
Appendix
A-16
Appendix
A-17
Appendix
A-18
Appendix
A-19
Appendix
A-20
Appendix
A-21
Appendix
A-22
Appendix
A-23
Appendix
A-24
Appendix
Partial Penetration (0.243 Weld Depth) Pressure Run Images
A-25
Appendix
A-26
Appendix
A-27
Appendix
A-28
Appendix
A-29
Appendix
A-30
Appendix
A-31
Appendix
A-32
Appendix
A-33
Appendix
A-34
Appendix
A-35
Appendix
A-36
Appendix
Full Penetration Pressure Run Images
A-37
Appendix
A-38
Appendix
A-39
Appendix
A-40
Appendix
A-41
Appendix
A-42
Appendix
A-43
Appendix
A-44
Appendix
A-45
Appendix
A-46
Appendix
A-47
Appendix
A-48
B
APPENDIX
Original Configuration Bending Moment Analysis Images
Figure B-1 Header Hoop Stress
B-1
Appendix
B-2
B-3
Appendix
Figure B-4 1st Principal Stress
B-4
B-5
Appendix
B-6
Figure B-7 Stress Intensity
B-7
Appendix
B-8
B-9
Appendix
Figure B-10 Tube Axial Stress
B-10
B-11
Appendix
B-12
B-13
Appendix
Figure B-14 Tube Hoop Stress
B-14
Partial Penetration (0.225 Weld Depth) Bending Moment Analysis Images
B-15
Appendix
B-16
Figure B-17 Header Hoop Stres
B-17
Appendix
B-18
B-19
Appendix
B-20
B-21
Appendix
B-22
B-23
Appendix
B-24
B-25
Appendix
B-26
B-27
Appendix
B-28
Partial Penetration (0.243 Weld Depth) Bending Moment Analysis Images
B-29
Appendix
B-30
B-31
Appendix
B-32
B-33
Appendix
B-34
B-35
Appendix
B-36
B-37
Appendix
B-38
B-39
Appendix
B-40
B-41
Appendix
B-42
Full Penetration Bending Moment Analysis Images
B-43
Appendix
B-44
B-45
Appendix
Figure B-46 1ST Principal Stress
B-46
B-47
Appendix
B-48
B-49
Appendix
B-50
B-51
Appendix
B-52
B-53
Appendix
B-54
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Devt of Tube Repair Techniques For HR Steam Generators

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Development of Tube Repair Techniques for Heat Recovery Steam Generators

Supporting Stress Analyses, Code Interpretation, and Internal Tube Repair

Development of Tube Repair Techniques for Heat Recovery Steam Generators

Technical Update, March 2006

EPRI Project Manager D. Gandy

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

Figure 2-1 Original Configuration 2-D Geometry (Side View)

Figure 2-4 View of Applied Pressure Loads

Figure 2-5 View of Applied Forces for Bending Moment Analysis

Bending Moment Application Results

Partial Penetration Repair (0.243" Weld Depth)

Partial Penetration Repair (0.243" Weld Depth)

Conclusions and Recommendations

National Board Interpretation 04-15

National Board Interpretation 04-15

Internal Tube Repair

Internal Tube Repair

Internal Tube Repair

Internal Tube Repair

Figure A-1 Header Hoop Stress

Figure A-2 Header Hoop Stress

Figure A-3 Header Hoop Stress

Figure A-4 Header Axial Stress

Figure A-5 Header Axial Stress

Figure A-6 Header Axial Stress

Figure A-7 1st Principal Stress

Figure A-8 1st Principal Stress

Figure A-9 1st Principal Stress

Figure A-10 Stress Intensity

Figure A-11 Stress Intensity

Figure A-12 Stress Intensity

Partial Penetration (0.225 Weld Depth) Pressure Run Images

Figure A-13 Header Hoop Stress

Figure A-14 Header Hoop Stress

Figure A-15 Header Hoop Stress

Figure A-16 Header Axial Stress

Figure A-17 Header Axial Stress

Figure A-18 Header Axial Stress

Figure A-19 1st Principal Stress

Figure A-20 1st Principal Stress

Figure A-21 1st Principal Stress

Figure A-22 Stress Intensity

Figure A-23 Stress Intensity

Figure A-24 Stress Intensity

Partial Penetration (0.243 Weld Depth) Pressure Run Images

Figure A-25 Header Hoop Stress

Figure A-26 Header Hoop Stress

Figure A-27 Header Hoop Stress

Figure A-28 Header Axial Stress

Figure A-29 Header Axial Stress

Figure A-30 Header Axial Stress

Figure A-31 1st Principal Stress

Figure A-32 1st Principal Stress

Figure A-33 1st Principal Stress

Figure A-34 Stress Intensity

Figure A-35 Stress Intensity

Figure A-36 Stress Intensity

Full Penetration Pressure Run Images

Figure A-37 Header Hoop Stress

Figure A-38 Header Hoop Stress

Figure A-39 Header Hoop Stress

Figure A-40 Header Axial Stress

Figure A-41 Header Axial Stress