ANSI ASME POM 101-2013 Performance-Related Outage Inspections.pdf

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1、AN AMERICAN NATIONAL STANDARD ASME POM 101-2013Performance-Related Outage InspectionsASME POM 101-2013Performance-Related OutageInspectionsAN AMERICAN NATIONAL STANDARDTwo Park Avenue New York, NY 10016 USADate of Issuance: January 17, 2014The next edition of this Standard is scheduled for publicati

2、on in 2019. There will be no writteninterpretations of the requirements of this Standard issued to this edition.Errata to codes and standards may be posted on the ASME Web site under the Committee Pages toprovide corrections to incorrectly published items, or to correct typographical or grammatical

3、errorsin codes and standards. Such errata shall be used on the date posted.The Committee Pages can be found at http:/cstools.asme.org/. There is an option available toautomatically receive an e-mail notification when errata are posted to a particular code or standard.This option can be found on the

4、appropriate Committee Page after selecting “Errata” in the “PublicationInformation” section.ASME is the registered trademark of The American Society of Mechanical Engineers.This code or standard was developed under procedures accredited as meeting the criteria for American NationalStandards. The Sta

5、ndards Committee that approved the code or standard was balanced to assure that individuals fromcompetent and concerned interests have had an opportunity to participate. The proposed code or standard was madeavailable for public review and comment that provides an opportunity for additional public i

6、nput from industry, academia,regulatory agencies, and the public-at-large.ASME does not “approve,” “rate,” or “endorse” any item, construction, proprietary device, or activity.ASME does not take any position with respect to the validity of any patent rights asserted in connection with anyitems menti

7、oned in this document, and does not undertake to insure anyone utilizing a standard against liability forinfringement of any applicable letters patent, nor assumes any such liability. Users of a code or standard are expresslyadvised that determination of the validity of any such patent rights, and t

8、he risk of infringement of such rights, isentirely their own responsibility.Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted asgovernment or industry endorsement of this code or standard.No part of this document may be reproduced in any

9、 form,in an electronic retrieval system or otherwise,without the prior written permission of the publisher.The American Society of Mechanical EngineersTwo Park Avenue, New York, NY 10016-5990Copyright 2014 byTHE AMERICAN SOCIETY OF MECHANICAL ENGINEERSAll rights reservedPrinted in U.S.A.CONTENTSFore

10、word ivCommittee Roster . vCorrespondence With the PTC Committee viIntroduction . vii1 Object and Scope . 12 Acronyms . 13 Guiding Principles. 14 Specific Equipment Considerations . 25 Instruments and Methods of Measurement 26 Report of Results 2Nonmandatory AppendicesA Air Heater (Tubular) . 3B Blo

11、wdown Tank . 6C Condenser Steam Side . 8D Condenser Water Box and Tube-Side Inspection Guidelines . 11E Cooling Tower Outage Inspection Guidelines . 14F Electrostatic Precipitator 19G Feedwater Heaters and Deaerators . 21H Heat Recovery Steam Generators . 24I Boiler Setting Air In-Leakage and Regene

12、rative (Rotary) Air HeaterInspection Guidelines 39J Boiler Steam- and Water-Side Outage Inspection Guidelines . 44K Safety Considerations 48iiiFOREWORDPOM 101, Performance Related Outage Inspections, is the first standard in a planned series ofpower plant performance operation and maintenance standa

13、rds. Related to and initially sponsoredand staffed by the Performance Test Code Standards Committee, these standards do not prescribetesting activities, but if followed will assist in the improvement of power plant performance andreliability.In June 2007, the Performance Test Code Standards Committe

14、e approved the charter for theseries of standards on operation and maintenance activities related to power plant performance.The ASME Board on Standardization and Testing approved this Standard on October 7, 2013. Itwas approved as an American National Standard by the ANSI Board of Standards Review

15、onDecember 4, 2013.ivASME PTC COMMITTEEPerformance Test CodesSTANDARDS COMMITTEE OFFICERSP. G. Albert, ChairJ. W. Milton, Vice ChairJ. H. Karian, SecretarySTANDARDS COMMITTEE PERSONNELP. G. Albert, General Electric Co.R. P. Allen, ConsultantJ. M. Burns, Burns Engineering ServicesW. C. Campbell, True

16、 North Consulting, LLCM. J. Dooley, Alstom PowerG. J. Gerber, ConsultantP. M. Gerhart, University of EvansvilleR. E. Henry, Sargent it is the second standard in the plannedseries of POM standards and will be published soon.viiINTENTIONALLY LEFT BLANKviiiASME POM 101-2013PERFORMANCE-RELATED OUTAGE IN

17、SPECTIONS1 OBJECT AND SCOPE1.1 ObjectThis Standard provides guidelines for equipmentinspections that are designed to ultimately improve thethermal performance or efficiency of the power plant.By following these guidelines, many issues identifiedduring an inspection, upon resolution, will also improv

18、ethe reliability of the plant.1.2 ScopeThis Standard provides guidelines for equipmentinspections of power plants using fossil fuels duringshutdown or outage periods. Some portions of this docu-ment may be applicable to other types of power plants.2 ACRONYMSThe following acronyms are used in this St

19、andard:AH: Air HeaterESP: ElectroStatic PrecipitatorFD: Forced DraftGT: Gas TurbineHP: High PressureHRSG: Heat Recovery Steam GeneratorIP: Intermediate PressureLOI: Loss On IgnitionLOTO: LockOut/TagOutLP: Low PressureNDT: NonDestructive TestingOEM: Original Equipment ManufacturerP do not relyon ment

20、al notes. This is critical to ensure all findingswill be included in the inspection report.(c) Obey all site safety rules.3.5 Postinspection ActivitiesThe following items should be completed immedi-ately following the inspection:(a) Report the significant findings from the inspec-tions to the respon

21、sible plant contacts.(b) Report any safety issues found to correct andremove the hazards.(c) Ensure all tools and materials taken on the inspec-tion are returned to their proper storage locations andthat nothing was left out in the field.(d) Sign out on the appropriate forms, as needed (suchas LOTO

22、or confined space permits).(e) Document all findings in a report that is retrievablein the future.(f) Summarize all recommended actions and alertappropriate personnel as needed for implementation.2(g) Plan for a reinspection if recommended actionsrequire it.4 SPECIFIC EQUIPMENT CONSIDERATIONSAdditio

23、nal documentation on specific equipment con-siderations is provided in the appendices.5 INSTRUMENTS AND METHODS OFMEASUREMENTThe following is a list of some of the instrumentationavailable to support equipment inspections:(a) digital/photographic cameraNOTE: Be sure to take notes with each picture i

24、nstrument ID,location, time, etc.(b) ultrasonic depth meters for determining wallthickness of metal pieces(c) rulers and tape measures(d) magnifying glasses6 REPORT OF RESULTSWhen reporting the results of an outage inspection,the following information should be included:(a) site information(b) date

25、and time of inspection(c) names, positions, and affiliations of personsinvolved in inspection(d) equipment included in inspection(e) purpose of inspection(f) instrumentation used during inspection(g) analytical methods used, if applicable(h) findings from inspection(i) conclusions and/or recommendat

26、ions(j) uncertainty considerations may be applicableto extrapolations of future expectations(k) appendices for data collected in support of inspec-tion, including(1) raw data and measurements(2) photos(3) drawings or sketches(4) P not all areasor items will pertain to every air heater.Equipment reli

27、ability and performance have parallels.Indications of poor performance are closely tied to thoseof reduced reliability. Abnormal wear patterns, poorcleanliness, increased corrosion, and mechanical fail-ures, no matter how small, have effects on both unitreliability and unit performance. Identifying

28、the rootcause is the first step in improving the overall perform-ance of a piece of equipment and the power generatingunit it is a part of. While these inspection guidelines arewritten to ultimately enhance the plants performance,all observations should be noted and acted upon.A-1.1 Prior to the Out

29、ageThe following should be conducted prior to theoutage:(a) Review the last inspection report.(b) Review recent operating historyair in-leakagepressure drops, both air and flue gas sidesefficiency and x-factortube leak history and mapabnormal operating events(c) Contact plant operations for addition

30、al informa-tion on operating history.(d) Obtain the following drawings of the air heaterprior to inspection to aid in the inspection and report/documentation:elevationpenetrationsinstrumentationlayout(e) It is recommended that thermography be used tolocate hot or cold spots on the external casing of

31、 the airheater while it is in service. Any spot varying more than10F from the general area should be documented, as itmay be caused by air in-leakage or loss of insulation.(f) Make a plan or checklist on the items and areasof interest that should be inspected. Identify which doors(manways) you plan

32、to use to enter and exit the airheater.(g) Make a safety plan and conduct a briefing priorto entering the air heater. Ensure all participants areaware of their responsibilities, including looking out for3each other, obeying the outside safety watch person, andevacuation plans.(h) Gather personal saf

33、ety equipment.(i) Gather cameras, flashlights, and writing equip-ment, and ensure sufficient lanyards are available for allequipment brought into the air heater.(j) If necessary, arrange for temporary scaffolding orladders.A-1.2 During the InspectionThe following should be conducted during the outag

34、e:(a) Record all information as observed; do not relyon mental notes. This is critical to ensure all findingswill be included in the inspection report.(b) Obey all instructions from the outside safety watchperson.A-1.3 After the InspectionThe following should be conducted after the outage:(a) Report

35、 the significant findings from the inspec-tions immediately to the responsible plant contacts.Safety issues require immediate reporting and correc-tion to remove the hazards.(b) Ensure all material brought into the air heater aspart of the inspection leaves with you.(c) Sign out on the appropriate f

36、orms.(d) Document all findings in a report that will beretrievable in the future.(e) Summarize all recommended actions.(f) Plan for a reinspection if recommended actionsrequire it.A-2 PROCEDURES PRIOR TO EQUIPMENTSHUTDOWNThe procedures to be followed prior to shutdown areas follows:(a) The equipment

37、 to be inspected should be takenout of service. Equipment clearances or tagouts shouldbe signed by appropriate personnel.(b) All energy sources, steam, soot blowers, fuels, andchemical injection equipment such as ammonia must beremoved from service.(c) Consider double block and bleed-valve isolation

38、for inspections if any connections exist to operatingunits.ASME POM 101-2013(d) If other boiler back-pass maintenance activities(e.g., economizer, cleaning, or replacement) will be con-ducted during the outage, this inspection should bescheduled to avoid those times when work will beoccurring direct

39、ly overhead. Mechanical parts and toolsare heavy and if dropped may present a serious threatto safety. If the ash hopper beneath the air heater hasbeen removed, the open areas should be covered to pre-vent unanticipated ingress of tools and personnel.(e) Inspecting an air heater involves heights, cl

40、osespaces, hard metal, sharp edges, and fly ash. Inspectorsshould be physically fit and able to climb. They shouldnot be bothered by feelings of claustrophobia.A-3 CONDUCTING THE INSPECTIONA tubular air heater inspection should be undertakenas a team effort. It is recommended that a minimum ofthree

41、individuals participate. Utilizing inspection teammembers from maintenance, engineering, and opera-tions will broaden the view and improve the findings.The participants may rotate as the outside safety watchor all three may enter simultaneously if the safety-watchfunction can be performed by another

42、 person. It is rec-ommended that one person serve as scribe and anothercarry the camera or video-recording device. The notes/records may be recorded in writing or via soundrecording to be transcribed immediately thereafter.Upon exiting the air heater, all notes, records, and photo-graphs should be d

43、uplicated and stored separately toensure preservation of this information.This tube-leak check is a multipart inspection firstprior to any cleaning, then after cleaning, and even laterif needed. The air side should not require cleaning; there-fore, one internal inspection of that portion of the airh

44、eater is sufficient.Many tubular air heaters are designed and built tocontain two separate banks of tubes, located in serieswith respect to flue gas flow. Two separate banks oftubes means double of nearly everything, from tubesheets to instrumentation. Ensure all notes andrecordings are accurately l

45、abeled for future reference tothe correct bank of tubes, e.g., upper or lower.A-3.1 Initial Inspection Before CleaningThe first inspection should be conducted prior to anycleaning activities in the air heater.Check the insulation on the interior of the casing walls;ensure it is all in place and none

46、 has fallen. Check theinterior casing walls for indications of air in-leakage.These may be manifested by discoloration or distinctivefouling.Photograph or sketch the locations of any debris. Pilesof ash may be significant; record their size and location.Look for wear patterns from soot blowers and l

47、ook forcleaning patterns to identify any area missed. These areevidenced by shiny spots or defined fouling patterns.4Note any signs of debris, foreign material, and corro-sion products. Material and tools may have been inad-vertently dropped from activities in the ductwork abovethe air heater. Ident

48、ifying the source of the foreign mate-rial will assist in preventing its recurrence. Large piecesof material may block the flow through a large numberof tubes, degrading the heat transfer capability of the airheater. A localized concentration of corrosion products istypically the indication of a pro

49、blem. A further investi-gation is warranted to determine the root cause andpotentially prevent recurrence.Check to ensure instruments and their connectionsare not buried, covered, or insulated by mounds of ashor other debris.A-3.2 Second Inspection After CleaningA second inspection should be conducted after theair heater is cleaned. This inspection will enable thoseentering the air heater to observe the actual mechanicalcondition of the components.Again, look for wear patterns from soot blowers andlook for cleaning patterns to identify any area missed.These are evidenced by