International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

Residual Life Assessment

Mr. Suraj C. Thombre Prof. M R. Kotwal
Department of Mechanical Engineering Associate Professor:
Y.C.C.E (An autonomous institution affiliated to RTMNU) Department of Mechanical Engineering
Nagpur, India Y.C.C.E (An autonomous institution affiliated to RTMNU)
Nagpur, India

Abstract-Predicting the residual life of plant equipment

otherwise be retired from service unnecessarily. This can
that has been in service for 15 to 25 years or more is a
major concern of many industries. This research paper mean lots of net savings to some companies.
reviews the reasons for increased concern for residual-life ІІ. WHAT IS RLA?
assessment and the general procedures used in performing
such assessment. Equipment was designed to work under certain
conditions and has certain expected life. If these
Keywords- Residual,RLA,steel,life
equipments are operated under harsher conditions then
І. INTRODUCTION their useful life is short. For the estimation of the residual
lifetime the maximum expected lifetime, assuming that the
Predicting the remaining operating life of plant
equipment will be operated under same conditions, has to
equipment that has been in service for many years is a
be found out. The expected lifetime is a function of the
problem faced by many industries and many power plants.
operating conditions. In dependence of the average load
The problem is especially for those companies whose
level it can get shorter for higher load conditions. The
plants have been in service for 15 to 25 years or more. This
residual lifetime can be defined as the difference between
research paper gives general introduction to the topic of
the expected lifetime and the actual age. For general
residual-life assessment. Analysis of reliability data plays
mechanical equipment the relationship between expected
an important role in the maintenance decision making
life and load conditions can be described as (Figure1)
process. The accurate estimation of residual life of in
components of equipment and system can be great asset
when planning the preventive maintenance. To get high
operational availability and stability in maintenance for
develop life extension of equipment. It is essential to
correct assessment of residual life of equipment. A lot of
confusion in the residual life assessment (RLA) technology
for service exposed machine components because simple
metallurgical analysis has often been passed on as RLA to
machine users by numerous independent consultants
including repair and overhaul businesses. These
metallurgical analysis based RLA reports provide a
recommendation for further use without providing any
substantial quantitative basis for life extension. In the
current economic and political climate, many companies
cannot afford to replace existing plants or major Figure 1 . Relationship between expected life and load conditions
components and must find a way to safely extend their ІІІ. METHODOLOGY SUGGESTED FOR
operating life. For them, reliable methods for predicting IMPLEMENTATION:
residual life are a must. Accurate, reliable predictions of
residual life provide a basis for timely, safe, and economic The mechanical equipments are normally expected to
replacement or repair of key components; they can help to fail due to aging or wear. Sometimes random failures occur
maximize a plant's usefulness by: due to causes which are external to the system. The
equipment is repaired and brought back to working
 establishing a sound, defensible basis for condition.
extending operating life,
 reducing costly unscheduled outages caused by in- The record of the conditions under which the equipment
service failures, has worked over the past period is extremely important for
 and eliminating unnecessary replacements.[1] RLE studies. This forms the basis and this information
coupled with other maintenance records will be very
Thus, proper implementation of residual-life prediction helpful. The general steps followed for carrying out RLE
methodology allows the continued use of plants that might studies are -

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

(a)Study of past performance data and review of 1. NDE TECHNIQUE:-

O&M records e.g. loading conditions, number of tripping
failures, repairs/replacements etc. Non-destructive testing (NDT) is a wide group of
analysis techniques used in science and industry to evaluate
(b)Assessment of present condition of the the properties of a material, component or system without
equipment, E.g. efficiency and operating parameters. causing damage. The terms Non destructive examination
(c)Assessment of remaining life of various (NDE), Non destructive inspection (NDI), and Non
equipment parts by conducting residual life estimation destructive evaluation (NDE) are also commonly used to
(RLE) studies. describe this technology. Common NDT methods include
ultrasonic testing, magnetic-particle inspection, liquid
(d) Identification of components requiring pentrant testing, remote visual inspection (RVI), eddy-
replacements, repairs, up-gradations/retrofitting. current testing.
(e) Formulation of R&M/Life Extension scheme 1.1 A Brief Description Of NDT Techniques:-
covering complete scope of works.
1.1.1 Ultrasonic Flaw Detection
This technique is used for the detection of internal and
ІV. VARIOUS TECHNIQUES USED FOR ASSESING
surface (particularly distant surface) defects in sound
PRESENT CONDITION
conducting materials. The principle is in some respects
The equipment which undergoes RLA studies, is similar to echo sounding. A short pulse of ultrasound is
completely dismantled and each and every part is inspected generated by means of an electric charge applied to a piezo
for damage and wear out. The parts which are critical for electric crystal, which vibrates for a very short period at a
proper operation of the equipment are inspected thoroughly frequency related to the thickness of the crystal. In flaw
using various Non Destructive Evaluation Techniques. detection this frequency is usually in the range of one
They are - million to six million times per second (1 MHz to 6 MHz).
[9]See figure 2.
1. Non destructive examination (NDE) technique
e.g., dimensional measurement, optical 1.1.2 Eddy Current Testing
observation, and ultrasonic, eddy current, X-ray. The main applications of the eddy current technique are
2. Metallographic examination, e.g., through-section, for the detection of surface or subsurface flaws and coating
outer surface, and plastic replication techniques. thickness measurement. The technique is sensitive to the
3. Risk-based inspections (RBI). material conductivity, permeability and dimensions of a
product. Eddy currents can be produced in any electrically
conducting material that is subjected to an alternating
magnetic field (typically 10Hz to 10MHz). The alternating
magnetic field is normally generated by passing an
alternating current through a coil. The coil can have many
shapes and can between 10 and 500 turns of wire. The
magnitude of the eddy currents generated in the product is
dependent on conductivity, permeability and the set up
geometry. Any change in the material or geometry can be
detected by the excitation coil as a change in the coil
impedance. The simple coil comprises a ferrite rod with
several turns of wire wound at one end and which is
positioned close to the surface of the product to be tested.
When a crack, for example, occurs in the product surface
the eddy currents must travel farther around the crack and
this is detected by the impedance change.[9] See figure 3.
Figure 2 . Ultrasonic flaw detection[9]

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ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

Figure 3 . Coil with single winding [9]

1.1.3 Dye Penetrant Testing completely and thin coating of developer is sprayed. After
a further period (development time) the developer draws
This method is frequently used for the detection of the dye out of the crack, to form a visual, magnified in
surface breaking flaws in non ferro-magnetic materials. width, indication in good contrast to the background. The
The subject to be examined is first of all chemically process is purely a chemical.[9] See figure 4.
cleaned, usually by vapour phase, to remove all traces of
foreign material, grease, dirt, etc. from the surface
generally, and also from within the cracks. Next the dye
(which is a very fine thin oil usually dyed bright red or
ultra-violet fluorescent) is applied and allowed to remain in
contact with the surface for approximately fifteen minutes.
Capillary action draws the dye into the crack during this
period. The surplus dye on the surface is then removed

Figure 4 . Illustration of Dye Penetrant Testing [9]

Figure5. Inspection of magnetic particles [9]

1.1.4 Magnetic Particle Inspection

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ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

This method is suitable for the detection of surface and radiation which is differentially absorbed by the material
near surface discontinuities in magnetic material, mainly through which it passes; the greater the thickness, the
ferritic steel and iron.The principle is to generate magnetic greater the absorption. Furthermore, denser material gives
flux in the article to be examined, with the flux lines greater absorption. X ray and Gamma rays also have the
running along the surface at right angles to the suspected property, like light, of partially converting silver halide
defect. Where the flux lines approach a discontinuity they crystals in a photographic film to metallic silver, in
will spray out in to the air at the mouth of the crack. The proportion to the intensity of the radiation reaching the
crack edge becomes magnetic attractive poles North and film, and therefore forming a latent image. This can be
South. These have the power to attract finely divided developed and fixed in a similar way to normal
particles of magnetic material such as iron fillings. Usually photographic film. Material with internal voids is tested by
these particles are of an oxide of iron in the size range 20 to placing the subject between the source of radiation and the
30 microns, and are suspended in a liquid which provides film. The voids show as darkened areas, where more
mobility for the particles on the surface of the test piece, radiation has reached the film, on a clear background. The
assisting their migration to the crack edges. However, in principles are the same for both X ray and Gamma
some instances they can be applied in a dry powder form. radiography. In X-ray radiography the penetrating power is
The particles can be red or black oxide, or they can be determined by the number of volts applied to the X-Ray
coated with a substance, which fluoresces under black tube - in steel approximately 1000 volts per inch thickness
light. The object is to present as great a contrast as possible is necessary. In Gamma radiography the isotope governs
between the crack indication and the material background. the penetrating power and is unalterable in each isotope.
[9]See figure 5. [9]
An illustration of Radiography shows in figure 6.
1.1.4 Radiography
This technique is suitable for the detection of internal
defects in ferrous and nonferrous metals and other
materials. X-rays, generated electrically, and Gamma rays
emitted from radio-active isotopes, are penetrating

Figure 6 . An illustration of Radiography [9]

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ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

1.5 Visual Inspection 2.1 Micro-structural phase evolution

Basic principal is that check the specimen with normal 2.2 Micro-void formation at grain boundaries
eye or under light.
2.3 Evolution of carbides (eutectoid and ferritic fine
• Visual Inspection Equipment precipitation)
1. Magnifying Glass 2.4 Inter particle distance
2. Magnifying Mirror 2.1.1 Micro-structural phase evolution:-This aspect is
mainly related to the effect of temperature and is not so
3. Microscope
strictly connected to load application. It is commonly
4. Boro-scope accepted as a qualitative thermal degradation index shown
through:
6. Video Image scope
- tendency to pearlite/bainite spheroidisation
2 METALLOGRAPHIC EXAMINATIONS:
- coarsening of precipitates in the ferritic matrix and at
2.1 Ferritic Steels
grain boundaries,
As far as this type of material is concerned, the aspects
- broadening of denuded zones (no precipitates) along
mainly considered valid as an index of creep exposure are:
grain boundaries.[4] see figure 7.

Figure 7 . Micro-structural phase evolution [4]

Expose time

Figure 8 micro-voids formation [7]

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Vol. 4 Issue 03, March-2015

2.1.2 Micro-voids formation at grain boundaries:-The order to find numerical correlation of the parameter with
principle is based on the fact that creep evolution of heat service and expected time of the component. In the
resistant steels is related to the appearance of cavities some research studies hardness has been measured through
time before rupture. These cavities gradually form micro- standard instruments as Vickers or Brinell indenter based,
cracks by inter-linkage and at the end come to initiate the but for in plant direct monitoring of serviced component
rupture. Size and density of the cavities increase as creep some instruments based on energy absorption during
progresses from secondary to tertiary. Cavity size is largely impact or indentation combined with ultrasonic
dependent also on material type, however it is in the range measurements are available as correlation for standard unit
of micron size (often also lower), therefore they are usually conversion. Due to this fact it is thus possible to obtain also
called “micro-voids” or ”micro-cavities”. Due to their results directly from in-service components. Actually at the
small size, they cannot be detected by conventional NDT moment although hardness measurement in plant is a
techniques such as PT, UT, MT, RT, and metallographic commonly applied technique during maintenance
investigation is required. [4] see figure 8. inspection (especially in combination with replica) the
most of the published studies are based on laboratory
2.1.3 Carbide evolution:-Many significant studies have measurement made on test specimens with standard
been conducted on the evolution of carbides present in hardness measurement techniques.[4]
steels due to creep exposure. Separation and coarsening of
carbides is in general an index of material degradation due 2.2.3 Risk-Based Inspections (RBI):-The risk-based
to creep exposure. The most important carbides are M3C inspection (RBI) methodology was introduced by Chinese
Essentially cementite Fe3C but often including other petrochemical enterprises from the beginning of this
metallic elements (in particular Mn), the content of these century, it has been put into practice fruitfully on the
other elements is controlled by element tendency to pressure-bearing systems of over 30 petrochemical plants,
partitioning among ferrite matrix and affinity to carbon for and the safety and economy of enterprise production have
carbide formation. improved. In the past several outstanding problems found,
helped in the development of RBI in China, for example,
2.1.4 Inter-particle distance:-The concept is strictly related with respect to the problem of acceptable risk, the principle
to phenomenon of carbide coarsening and grain boundary of "equal risk level", and similarly, the determination of
area the microstructure transformation correspond in an inspection cycle, effectiveness of online inspection,
inter-particle distance growth that can be statistically relationship with statutory regulations and technical
(roughly or more precisely) estimated. specifications, software introduction and improvement,
2.2 Techniques Applied For Investigation On In-Service etc., are used to get the definite suggestions.[4]
Components V. RESIDUAL LIFE ASSESSMENT
The most of the studies done on correlation of material 1. Using Damage Parameter
microstructure and creep exposure have been performed by
means of metallographic specimen obtained from creep In high pressure and high temperature components,
specimen after tests. A large improvement of the headers & steam pipes, the consequential damage
investigation on actual in service components has been mechanism is creep, which manifests itself in the form of
obtained with the replica technique. cavities in the microstructure. The morphology (shape
characteristics and orientation) of the cavities shows the
2.2.1 Replica investigation:-The technique is essentially the status of the component in terms of its remaining life. The
application of metallographic specimen preparation phenomenon of creep is guided by the factors such as
(grinding, polishing, and etching) to a limited area of the temperature, stress, time and material properties. Given a
component that is required to investigate and the material that is subjected to constant temperature and stress
reproduction of the so prepared surface on a thin foil of (pressure), creep damage evident in the microstructure will
polymeric material. If microstructure evolution is the target be a function of time (expended life fraction).
of replica examination, the removal of a thin layer of
surface material (about 0.3-0.5 mm thickness reduction) is Fatigue Usage Fraction:-
recommended so to avoid the external layer of
The maximum stress developed due to thermal pressure.
decarburized material. The reproduction of prepared
Take alternating stress range (S range), with the lower limit
surface on plastic material is achieved by the softening of
zero towards the max in the shut down condition, fatigue
polymeric thin foil with adequate solvent followed by
life usage fraction is obtained from S-N curve as
hardening of the same plastic material due to solvent
evaporation. Replica can be observed with the utilization of Uf= n/N
an optical microscope, where standard magnification
ranges from50 to 500 x ( 1000 x magnification can be Where, n is the actual number of stress cycles
achieved but often difficulties can be matched on focus experienced by the component, and N is the maximum
optimization of replica surface). number of stress cycles that the component can
withstand.[8]
2.2.2 Hardness:-Since the first study developed for the
assessment of residual life in high temperature serviced S-N Curve :-These curves represent the relationship
components, attention has been paid to hardness value in between the stress Range and corresponding fatigue life

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ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

„N‟ measured in terms of number of stress cycles to failure. X – oxide scale thickness in mils
To develop these curves, fatigue tests are conducted in
P – T (20 + log t ) [ Larsen miller parameter ]
laboratory on representative samples. For each stress range
different values of number of cycles till failure are T – temperature in 0 R (0 F + 460 )
obtained. S-N curves have been developed based on data of
full size specimen of different types of connections. See t- time in hour
figure 9. Tr = t × Texp
Where Tr = reaming time in hours, Texp = running hours

VІ. RENOVATION AND MODERNIZATION

Predictive maintenance is becoming more popular as a
productivity tool. It helps to eliminate unscheduled
downtime of equipment and reduce the overall cost of
maintenance. The performance of equipment can be
analyzed to determine its condition and predict when it will
need attention. The concept of simple replacement of
power equipment in the system, considering it as weak or a
potential source of trouble, is no more valid in the present
scenario of financial constraints. Today the paradigm has
N Cycles to failure changed and efforts are being directed to explore new
approaches/techniques of monitoring, diagnosis, life
assessment and condition evaluation, and possibility of
Figure 9. Stress to number cycle graph extending the life of existing assets. Renovation and
modernization and life extension of equipment is one of the
Where stress range and N is is number of stress cycles to
cost effective option for maintaining continuity and
failure.
reliability. R&M is primarily needed to arrest the poor
Creep Usage Fraction:- Maximum stress due to pressure performance of the equipment which are under severe
and load condition, creep life usage fraction (Uc) is stress due to poor grid conditions, poor and inadequate
obtained from creep curve at operating temperature. Creep maintenance and polluting environment. The methodology
life usage fraction is given by the ratio t/tr. of implementation of R&M and life extension schemes and
the essential inputs required for its successful
Where t is total duration in hour and tr total time from s-t implementation have been suggested.[3]
curve. [8]
Need for Renovation and Modernization:
Residual Life Estimation:-Theoretically, residual life
fraction of component is given by 1) Deterioration in performance due to aging, poor
maintenance etc.
RLF = 1 – Uf – Uc.
2) Deterioration in performance due to design deficiencies,
However, due to many factors influencing fatigue and pollution etc
creep such as deviations from design during manufacture
and operation, notches, surface finish, size of component 3) Non-availability of spares due to obsolescence.
and creep-fatigue interaction, which are not theoretically Objective of Renovation and Modernization:
estimated.
a) To arrest the deterioration in performance.
Residual life fraction is given by:-
b) To improve the availability, reliability, efficiency and
RLF = (½) – Uf – Uc.[8] safety of the equipment.
2.Oxide Scale Thickness Method c) To regain lost capacity
It is related to corrosion which are formed on the d) To extend the useful life beyond designed life of 25
material. The severely corrosion affected area was years.
examined with penetrating liquids and ultra sounds.
e) To save investments on new equipment
The Remaining Life is calculated based on the oxide
f) To meet environmental pollution norms and to have
scale measured with the optical microscope and or other
more effective pollution control.[3]
non-destructive methods by using the following formulae:
In practice, residual-life assessment may be applied to a
Log X = 0.00022 P – 7.25
single component, a major subsystem, or an entire plant. A
P = T ( 20 + log t ) systematic assessment procedure needs to be developed to
prioritize, select, and integrate appropriate methods tailored

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ISSN: 2278-0181
Vol. 4 Issue 03, March-2015

to the specific problem under consideration. The procedure

would identify the likelihood of success and the
costs/benefits for applying a given method. It would
provide a framework for:
 assessing the system to identify critical
components,
 selecting measurement, sampling, and
computational methods,
 making life-extension recommendations, and
 Evaluating the economics of implementing those
recommendations.
VІІ. CONCLUSION
In this paper, the overall concept of about residual life
estimation is presented. Various techniques useful for
finding present condition of component are studied. The
methodology of Residual Life Estimation is discussed. The
importance of past data and various damage causing
mechanisms is shown.
VІІІ. REFERENCES:
1. C.E. Jaske Battelle's Columbus Laboratories “Predicting The
Residual Life Of Plant Equipment” Journal of Pressure Vessel
Technology AUGUST 1985, Vol. 107/213.
2. Xuedong Chen *, Zhibin Ai, Tiecheng Yang, Bing Wang, Wangping
Gu “Evaluation Method Of Failure Probability With Residual Life
As The Reference In Risk-Based Inspection (RBI) “National
Technical Research Center On Safety Engineering Of Pressur
Vessels And Pipelines, Hefei General Machinery Research Institute,
Hefei 230031, China
3. A. Amitabh Srivastava, Agm(Ste) Bhel, Haridwar
B. Vivek Sharan, Manager (Ste) Bhel, Haridwar
“Residual Life Assessment (RLA) Based Renovation &
Modernization (R&M) Of Steam Turbines” International Conference
& Exhibition India Thermal Power-4
4. Eccc Recommendations - Volume 6 [Issue 1] Residual Life
Assessment And Microstructure
5. Association Of Local Government Engineers New Zealand:
"Infrastructure Asset Management Manual", June 1998 - Edition 1.1
6. Mark Willcox & George Downes A Brief Description Of NDT
Techniques
7. Praful R Dongre, Vibhav B Rakhunde “Residual LifE Assessment
In High Temperature Zones Of Power Plant Components”
International Journal Of Mechanical And Production Engineering,
ISSN: 2320-
8. Srikanth Bashetty, Parthasarathy Garre, J. Ramesh Babu, Likhitha
Chodisetty “Coupled Thermal-Structural Analysis of a Turbine
Rotor Using ANSYS for Finding Out Remnant Life” . The
International Journal Of Science & Technoledge (ISSN 2321 –
919X).
9. Mark Willcox & George Downes “A Brief Description of NDT
Techniques” Insight NDT Equipment Limited, 2000 – 2003.
www.InsightNDT.com

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