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1 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Daily Schedule
2 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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PROGRAMME OBJECTIVES
Understand FFS for static, mechanical equipment
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Programme
DAY 1 FOUNDATIONS OF FITNESS-FOR-SERVICE ASSESSMENT
Introduction to Fitness For Service Assessment
ASME Construction Codes
PART 3 Brittle Fracture
PART 4 General Metal Loss
`
DAY 2 MECHANICAL INTEGRITY AND FITNESS FOR SERVICE
PART 5 Local Metal Loss
ANNEX A Thickness, MAWP & Stress equations for a FFS Assessment
PART 6 Pitting Corrosion
PART 7 Hydrogen Blisters, HIC & SOHIC
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STRENGTH
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What is FFS?
ASME and API codes for pressurized equipment do not
address in-service equipment degradation nor deficiencies in
original fabrication.
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What is FFS?
An FFS assessment is an engineering analysis of equipment to
determine whether it is fit for continued service.
The equipment may contain flaws, may not meet current design
standards, or may be subject to more severe operating conditions
than the design conditions.
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Continue In Service?
The following questions are frequently asked regarding the
mechanical integrity of the equipment in question:
"What would be the most effective way to detect and monitor the
damage?"
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FFS assessments
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FFS Assessment
A "fitness-for-service" (FFS) assessment
demonstrates that failure of the defective
component will not occur by any recognized failure
mechanism within a reasonable time.
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Technical Integrity
Plan:
Specifications
Specifications Risk Reliability Management
Procedures
Procedures Asset Register
Standards
Standards
Action:
Preventive Maintenance
Improve: Corrective Maintenance
Change Management Inspection
Modification Projects Operation
Analyse:
Root Cause Analysis
Fitness for Purpose
Check:
Deviation Control
Technical Authorities
Risk Management
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Introduction
2000 - The first edition of API 579 produced by API CRE FFS Task
Group becomes the de facto international Fitness-For-Service (FFS)
Standard for pressure containing equipment in the refining and
petrochemical industries
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API 579-1/ASME FFS-1 2007 standard includes all previous topics and
also includes new parts covering FFS assessment procedures that
addresses unique damage mechanisms experienced by other industries
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Organization of Annexes
Annex A Thickness, MAWP, and Stress Equations for a FFS Assessment
Annex B Stress Analysis Overview for a FFS Assessment
Annex C Compendium of Stress Intensity Factor Solutions
Annex D Compendium of Reference Stress Solutions
Annex E Residual Stresses in a FFS Evaluation
Annex F Material Properties for a FFS Assessment
Annex G Deterioration and Failure Modes
Annex H Validation
Annex I Glossary of Terms and Definitions
Annex J Currently Not Used
Annex K Crack Opening Areas
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FFS Methods
Based on a variety of the American and British codes and
standards, such as
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FFS assessments
Part of the plant life management process
as a means of increasing
Availability
Reliability
Efficiency and
Safety.
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FFS Requirements
Require an interdisciplinary approach with
operations personnel consisting of an
understanding of
Damage mechanisms and material behaviour.
Past and future operating conditions.
Non-destructive examination techniques (flaw location
and sizing).
Material properties (environmental effects).
Stress analysis (finite element analysis; FEA) and
Data analysis (engineering reliability models).
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Damage to a component
can occur in many forms
such as:
Mechanical damage
Overload
Overheating
Corrosion
Erosion
Fatigue
Creep and
Hydrogen
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Damage Mechanisms
Regardless what materials in what process
conditions, the symptoms of corrosion damage
normally exhibit in the following forms:
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Other codes
When evaluating other codes and standards
the following should be considered:
Material specifications
Upper and/or lower temperature limits for specific materials
Material strength properties & design allowable stress basis
Material fracture toughness requirements
Design rules for shell sections
Design rules for shell discontinuities such as nozzles
Design requirements for cyclic loads.
Design requirements for operation in the creep range
Weld joint efficiency or quality factors
Fabrication details and quality of workmanship
Inspection requirements, particularly for welded joints
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Flaw evaluation
general and localized corrosion
widespread and localized pitting
blisters and laminations
weld misalignment and shell distortions
crack-like flaws including environmental cracking
to brittle fracture
long-term creep damage
fire damage
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ENGINEERING
ASSESSMENT
PROCEDURE
30 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Is fitness-for-service a qualitative
method based on judgment?
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Level 2 Assessment
Includes components requiring more
complex calculations such as nozzles
and flanges
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PROCEDURE
1 - Damage mechanism
2 - Applicability
3 - Input data
4 - Analysis
5 - Remaining life prediction
6 - Remediation and repair
7 - In-service monitoring
8 - Documentation
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Component is acceptable if
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Overview of an
FFS Analysis for
Crack-Like Flaws
Using the
Failure Assessment Diagram
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7.0 Blisters, HIC & SOHIC assessment procedures are provided in this Part for low strength ferritic steel pressurized components with hydrogen induced
cracking (HIC) and blisters, and stress oriented HIC (SOHIC) damage
8.0 Weld misalignment and shell Provides assessment procedures to evaluate stresses resulting from geometric discontinuities in shell type structures including weld
distortions misalignment and shell distortions (for example, out-of-roundness, bulges and dents).
11.0 Fire damage Provides assessment procedures to evaluate equipment subject to fire damage.
Provides a methodology to rank and screen components for evaluation based on the heat exposure experienced during the fire.
Refers to assessment procedures in the other sections of this publication to evaluate component damage.
12.0 Dents & Gouges Procedures for pressurized components containing dents, gouges, or dent-gouge combinations resulting from mechanical damage.
The procedures can be used to qualify a component for continued operation or for determining a reduced maximum
allowable working pressure
13.0 Laminations Assessment procedures for pressurized components with laminations, excluding HIC or SOHIC damage
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Sensitivity Analysis
Consider different assumptions with regard to
loading conditions,
material properties and
flaw sizes
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Probabilistic Analysis
Evaluate dependence of
safety margin on uncertainty
of independent variables
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REMAINING LIFE
Remaining life for general metal loss
t am t m in
R life
C rate
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Documentation
The equipment design data, and maintenance and past operational history to
the extent available should be documented for all equipment subject to a FFS
assessment.
1. Part, edition, and assessment level of this Standard and any other supporting
documents used to evaluate the flaw or damage.
2. Future operating and design conditions including pressure, temperature and
abnormal operating conditions.
3. Calculations of the minimum required thickness and/or MAWP.
4. Calculations of remaining life and the time for the next inspection.
5. Any remediation or mitigation/monitoring recommendations that are a condition for
continued service.
Brittle
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend Fracture
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API
52 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
API Background
1924 first standard released
(interchangeability of oil field equipment )
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API History
Origin during World War I, when Congress and the domestic
oil and natural gas industry worked together to help the war
effort.
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56 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
ASME
American Society of Mechanical Engineers was
founded in 1880
now >100,000 members
Programmes include
education,
technical conferences and exhibits
government relations
public education
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Individual Volumes
I- Power Boilers
II - Materials
III - Rules for Construction of Nuclear Power Plant Components
IV - Heating Boilers
V- Nondestructive Examination
VI - Recommended Rules for the Care and Operation of Heating Boilers
VII - Recommended Guidelines for the Care of Power Boilers
VIII - Pressure Vessels
IX - Welding and Brazing Qualifications
X- Fiber-Reinforced Plastic Pressure Vessels
XI - Rules for Inservice Inspection of Nuclear Power Plant Components
XII - Rules for Construction and Continued Service of Transport Tanks
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Division 2
alternative (more rigorous) to the minimum requirements for
pressure vessels under Division 1 rules (no max)
Division 3
design, fabrication, inspection, testing, and certification of fired or
unfired pressure vessels operating at either internal or external
pressures generally above 10,000 psi. (no minimum)
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It is a quantitative technique.
YOU NEED A LAPTOP WITH MS-
EXCEL or equivalent
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Note: ASME B31.4 and ASME B31.8 include rules for the evaluation
of local corroded areas, based on 1970s ASME B31.G.
Note: NBIC NB-23 contains simple rules for evaluation of corrosion.
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Is fitness-for-service a code?
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STRESS DISTRIBUTION
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BASIC EQUATION
CYLINDRICAL SHELL
Hoop (circumferential) stress
PD PR
hoop
2t t
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EXERCISE
HOOP STRESS
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OVERPRESSURE FAILURE
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PR
t
(SE 0.6P )
m in
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EXERCISE
ASME VIII SHELL
P = 690 kPa
S = 121 MPa SA 515-70 plate @
343oC
E = 0.85 (spot examination)
R = 1219mm
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CYLINDRICAL SHELLS
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SPHERICAL HEAD
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SPHERICAL HEAD
Spherical or hemispherical head (ASME VIII, UG-27)
PL
t min
( 2 SE 0.2 P )
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P = 690 kPa
S = 121 MPa psi SA 515-70
plate @ 343oC
E = 0.85 (spot examination)
R = 1219mm
What is the ASME VIII Div.1
required wall thickness of the
spherical head?
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ELLIPSOIDAL HEAD
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ELLIPSOIDAL HEAD
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ELLIPSOIDAL HEAD
Elliptical head (ASME VIII, Ap.I)
PD ( K )
t min
2( SE 0.2 P )
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ELLIPSOIDAL HEAD
E
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EXERCISE -
ELLIPSOIDAL HEAD
P = 690kPa
S = 121MPa SA 515-70
plate @ 343oC
E = 1.0
R = 1219mm
What is the ASME VIII
Div.1 required wall
thickness of the
2:1ellipsoidal head?
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TORISPHERICAL HEAD
(FLANGED AND DISHED HEAD)
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TORISPHERICAL HEAD
Torispherical head
[Flanged and dished]
(ASME VIII Ap.I)
0.885PL
t min
2SE 0.1P
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FLAT HEAD
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FLAT HEADS
Flat Heads
CP
t d
SE
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EXERCISE
ASME VIII FLAT HEAD
P = 690 kPa
S = 121 MPaSA 515-70 plate @
343oC
E = 1.0 (seamless)
R = 1219mm
What is the ASME VIII Div.1 required
wall thickness of the flat head?
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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EXERCISE
Pressure vessel
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PIPING SYSTEMS
ASME B31.1 - ASME B31.3
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Seamless = 1.0
Furnace butt weld = 0.6
Electric fusion arc weld = 0.8
Electric resistance weld = 1.0
Double submerged arc weld = 1.0
Values of y
T < 900oF = 0.4
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EXERCISE
ASME B31.3 PIPING
P = 690kPa
S = 121 MPa carbon steel pipe @
343oC
W = 1.0 (seamless)
Pipe = 10 Sched 40 (254mm OD)
What is the B31.3 required pipe
wall thickness?
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Nominal Pipe Schedule Number Wall Inside Weight per Weight of Moment of Section Modulus
Size Outside Thickness (in) Diameter (in) ft (lb) water per ft Inertia (in4) (in3)
Diameter, in. (lb)
a b c
1/8 - - 10S 0.049 0.307 0.2 0.03 0.0009 0.0044
0.405 40 Std 40S 0.068 0.269 0.2 0.02 0.0011 0.0053
80 XS 80S 0.095 0.215 0.3 0.02 0.0012 0.0060
1/4 - - 10S 0.065 0.410 0.3 0.06 0.0028 0.0103
0.540 40 Std 40S 0.088 0.364 0.4 0.05 0.0033 0.0123
80 XS 80S 0.119 0.302 1.1 0.03 0.0114 0.0325
3/8 - - 10S 0.065 0.545 0.4 0.10 0.0059 0.0174
0.675 40 Std 40S 0.091 0.493 0.6 0.08 0.0073 0.0216
80 XS 80S 0.126 0.423 0.7 0.06 0.0086 0.0255
1/2 - - 10S 0.083 0.674 0.7 0.15 0.0143 0.0341
0.840 40 Std 40S 0.109 0.622 0.9 0.13 0.0171 0.0407
80 XS 80S 0.147 0.546 1.1 0.10 0.0201 0.0478
160 - - 0.187 0.466 1.3 0.07 0.0221 0.0527
- XXS - 0.294 0.252 1.7 0.02 0.0242 0.0577
3/4 - - 5S 0.065 0.920 0.7 0.29 0.0245 0.0467
1.050 - - 10S 0.083 0.884 0.9 0.27 0.0297 0.0566
40 Std 40S 0.113 0.824 1.1 0.23 0.0370 0.0706
80 XS 80S 0.154 0.742 1.5 0.19 0.0448 0.0853
160 - - 0.218 0.614 1.9 0.13 0.0527 0.1004
- XXS - 0.308 0.434 2.4 0.06 0.0579 0.1104
1 - - 5S 0.065 1.185 0.9 0.48 0.0500 0.0760
1.315 - - 10S 0.109 1.097 1.4 0.41 0.0757 0.1152
40 Std 40S 0.133 1.049 1.7 0.37 0.0874 0.1329
80 XS 80S 0.179 0.957 2.2 0.31 0.1056 0.1607
160 - - 0.250 0.815 2.8 0.23 0.1252 0.1904
- XXS - 0.358 0.599 3.7 0.12 0.1405 0.2137
1-1/4 - - 5S 0.065 1.530 1.1 0.80 0.1038 0.1250
1.660 - - 10S 0.109 1.442 1.8 0.71 0.1605 0.1934
40 Std 40S 0.140 1.380 2.3 0.65 0.1948 0.2347
80 XS 80S 0.191 1.278 3.0 0.56 0.2419 0.2914
160 - - 0.250 1.160 3.8 0.46 0.2839 0.3421
- XXS - 0.382 0.896 5.2 0.27 0.3412 0.4111
1-1/2 - - 5S 0.065 1.770 1.3 1.07 0.1580 0.1663
1.900 - - 10S 0.109 1.682 2.1 0.96 0.2469 0.2599
40 Std 40S 0.145 1.610 2.7 0.88 0.3100 0.3263
80 XS 80S 0.200 1.500 3.6 0.77 0.3913 0.4119
160 - - 0.281 1.338 4.9 0.61 0.4825 0.5079
- XXS - 0.400 0.950 5.8 0.31 0.4205 0.4806
2 - - 5S 0.065 2.245 1.6 1.72 0.3150 0.2652
2.375 - - 10S 0.109 2.157 2.6 1.58 0.4993 0.4205
40 Std 40S 0.154 2.067 3.7 1.45 0.6659 0.5608
80 XS 80S 0.218 1.939 5.0 1.28 0.8681 0.7311
160 - - 0.343 1.689 7.4 0.97 1.1626 0.9790
- XXS - 0.436 1.503 9.0 0.77 1.3116 1.1045
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LONGITUDINAL STRESS IN
PIPING SYSTEM
Weight, expansion,
wind, waves, vibration,
etc. bend the pipe.
This causes a
longitudinal bending
stress.
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LONGITUDINAL STRESS IN
PIPING SYSTEM
The bending stress due to a bending moment M is
M
Sbending 0.75i
Z
Exercise:
The bending moment due to weight is
M = wL2/10
M = maximum bending moment, in-lb
w = weight per unit length, lb/in
L = span length, in
What is the maximum bending stress in the pipe span of a 6
sch.40 pipe full of water? (use i=1)
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ASME B31.4
OIL - LIQUID PRODUCTS PIPELINES
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S = 0.72 E Sy
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EXERCISE
OIL PIPELINE B31.4
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LONGITUDINAL STRESS IN
PIPELINE
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ASME B31.8
GAS PIPELINE
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Values of T
T < 250oF T = 1.0
T < 300oF T = 0.967
T < 350oF T = 0.933
T < 400oF T = 0.900
T < 450oF T = 0.867
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EXERCISE
GAS PIPELINE B31.8
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API 579
FITNESS-FOR-SERVICE
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Brittle Fracture
108 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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What happened?
2007 in Pembroke, Wales.
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Brittle Fracture
Level 1
compliance with new construction code exemption curves
or impact test requirements
Level 2
include consideration of low stress-based temperature
reduction rules
exemption based on hydrotest
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Assessment Requirements
Summary of repairs and alterations
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Data
Determine CET loading-temperature envelope
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LEVEL 1 ASSESSMENT
CURVES
A TO D
Assignment Of Materials To The
Material Temperature Exemption
Curves In Figure 3.4
API 579/ASME FFS Page 3-19
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EXERCISE
A horizontal drum 40mm wall thickness is fabricated from
ASTM A516 Gr.70 steel, supplied in the normalized condition.
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Cr-Mo-V vessel
16.76m long x 1.575m x
142,5mm wall
Hydrotest P = 48,650kPa at
10oC ambient
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EXERCISE
What is the hoop stress in the cylindrical shell of the
CR-Mo-V vessel during hydrotest at 48,650kPa?
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CET - MAT
Critical Exposure Temperature (CET):
Lowest temperature at which component exposed to
Pressure vessels and piping: 30% MAWP
Tanks:
hydrotest temp.
daily min. operating temp. + 15oF (8oC)
Level 2 Assessment
Pressure Vessels
Method A (3.4.3.1)
Safe operating envelope
MAT Temperature reduction rules
Method B (3.4.3.2)
Hydrotest
Consider METAL temperature
Method C (3.4.3.3)
Wall thickness <12.5 mm
Operational history
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Level 2 Assessment
Piping Systems
Method A (3.4.3.4)
Safe operating envelope
Use 3.4.3.1 if op stress < allowable stress
Method B (3.4.3.5)
Hydrotest
Consider sustained/thermal loads
Method C (3.4.3.6)
Figure 3.9 flowchart
Thickness < 38mm
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Level 2 Assessment
Storage Tanks
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Figure 3.10M Exemption Curve for Tanks Constructed From Carbon Steel of Unknown
Toughness Thicker Than 12.7 mm And Operating at A Shell Metal Temperature Below 16C
API 579/ASME FFS Page 3-42
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Level 3
Detailed determination of 1 or more:
stress,
flaw size
material toughness
Material Toughness
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Avoidance???
Use notch tough parent material, HAZ & weld metal or ductile stainless
steel or non-ferrous metal. Avoid structural notches.
Good welding, WPQ, Qualified welder, NDE, QA, Inspection etc. Use low
H2 electrodes, controlled heat input, fine grain low O 2 weld metal
Keep applied stress low e.g. higher safety factor, accurate shape to reduce
local bending/discontinuity stress.
Use slow heating and cooling or thermal sleeve to reduce thermal stress.
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General Corrosion
Based on local thin area assessment rules
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Level 1 Analysis
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C.O.V.
Calculate the average thickness (minimum 15)
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Coefficient of Variation
Location Thickness reading (trd, i - tam) (trd, i - tam)2
trd, i i=1 to N
1
2
3
4
5
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Level 1 (cont.)
Based on CTP
L=Q(Dtmin)
If s< L, OK for meridional corrosion, check longitudinal
corrosion using LTA Level 1 chart
If s>L, use point thickness readings with tam=tmm, or
determine average and minimum thickness for circumferential
and meridional directions
determine tam over length L centered on tmm
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EXERCISE
Pressure vessel
Design pressure/Temp. = 2068kPa
Inside diameter/wall thickness = 1292mm / 19mm
Corrosion allowance = 2.5mm
Material = SA 516 Grade 70
Weld joint efficiency = 0.85
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EXERCISE
Results of ultrasonic readings show a corrosion zone along
the longitudinal weld.
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Data Evaluation
Level 1 Assessment
Type A Components subject to internal pressure or
external pressure (i.e. supplemental loads are assumed
to be negligible).
Level 2 Assessment
Type A or B Components (see Part 4, paragraph 4.2.5)
subject to internal, v external pressure, supplemental
loads (see Appendix A, paragraph A.2.6), or any
combination thereof.
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EXERCISE
C1 C2 C3 C4 C5 C6 C7 C8
M1 19 19 19 19 19 19 19 19
M2 19 12.2 13.2 14.48 14.22 14.73 15.25 19
M3 19 14.5 15 14 15 15.25 16.76 19
M4 19 15.5 11.9 14.73 9.15 14.73 16.25 19
M5 19 16 15 14.73 14.48 12.2 15.75 19
M6 19 14.48 15 15.49 14.48 14.25 12.45 19
M7 19 19 19 19 19 19 19 19
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CORROSION
PROFILE
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Coefficient of Variation
Determine the COEFFICIENT OF VARIATION.
If the Coefficient Of Variation (COV) of the thickness readings is greater than 10%,
then use thickness profiles
If using Critical Thickness Profile the minimum distance between the readings
is:
LS min{0.36 Dtmin ;2trd } min{0.36 1292 16.5;2 19} 38mm
LS = grid spacing, mm
D = outer diameter, mm
tmin = minimum code required wall, mm
tnom = nominal wall thickness, mm
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Level 1 STEP 2
STEP - 2. Measure thickness profile.
20
19 19
18
16
14 14
12 12.2 11.9 12.2 12.45
10 CTP
9.15
8 tmin
6
4
2
0
1 2 3 4 5 6 7 8
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LEVEL 1 - STEP 3
Determine thickness for assessment
tc = 19mm 2.5mm
= 17.5mm
Step 4
Remaining thickness ratio
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LEVEL 1 - STEP 5
2
2
1 0.403
1 Rt
Q 1.123 1 1.123 1 0.461
Rt 1 0.403
1 RSF
0.9
a
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Table 4.5
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Determining s and c
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S in CTP
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LEVEL 1 - STEP 6
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Level 1 Step 7
Based on the parameters L and s from STEP 4 and STEP 5,
respectively, perform the FFS assessment of the region of metal loss
using one of the following methods
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LEVEL 1 - CONCLUSION
If wall thinning does not comply with level 1
assessment. Proceed with level 2
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LEVEL 2 STEPS 1 to 6
Same Procedure for
Type A components
different acceptance
criteria (Table 4.4)
Type B components
use Annex A criteria
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Level 2 STEP 7
STEP - 7. For pressure vessels and piping, the average
measured thickness should satisfy the following:
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EXERCISE
14 STD. Pipe (ID=336.65mm)
P = 800 psi @ 100oF (5516kPa @ 37.8oC)
ASTM A 106 Grade B
Design corrosion allowance was 0.10 (2.5mm)
Measured UT wall as given @ 1/4 (6mm) intervals.
0.375-0.375-0.200-0.200-0.150-0.200-0.375
(9.5mm -9.5mm-5.1mm-5.1mm-3.81mm-5.1mm-9.5mm)
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165 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Evaluation Methods:
API 579 Section 5 Level 1
Modified B31G, 0.85 DL
RSTRENG
B31G
Thickness avg 510
Thickness avg 653
British Gas
BS 7910, isolated defect
BS 7910, group defects
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EXERCISE
Pressure vessel
Design pressure/Temperature = 300 psi/650oF (2068kPa @ 330oC)
Inside diameter/wall thickness = 96 in/1.25 (2438mm/31.75mm)
Corrosion allowance = 0.125 in (2.5mm)
Material = SA 516 Grade 70
Weld joint efficiency = 0.85
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EXERCISE
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30
25
20
Series1
15
10
0
1 2 3 4 5 6 7 8 9
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LEVEL 1
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Level 1 STEP 2
Determine the thickness to be used.
May be determined using Equation (5.4).
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LEVEL 1 - STEP 3
Determine the minimum measured thickness in the LTA , t mm, and
the dimension, s.
(same as in Part 4 4.3.3.3)
t mm = 11.43mm
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LEVEL 1 - STEP 4
Calculate the length below tmin (24.93)
35
30
25
20
Series1
15
10
s = 42mm
5
0
1 2 3 4 5 6 7 8 9
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LEVEL 1 - STEP 5
Step - 4. Check the limiting flaw size. If these conditions are
not met, the flaw is not acceptable per Level 1.
Condition # 1
Rt 0.20
0.33 > 0.20 True
Condition # 2
tmm FCA 2.5mm (0.1) 11.43 2.5 = 8.93 > 2.5
True
Condition # 3
1.8 Dtc Lmsd 1.8 2438 26.71 459.3mm 1600mm
True
If these conditions are met, continue to step-6.
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LEVEL 1 - STEP 6
Groove parameters
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LEVEL 1 - STEP 6
Step - 6. If there is no groove or gouge, then go
to step-7. If there is a groove or gouge, then
verify the following:
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LEVEL 1 - STEP 7
Determine the MAWP for the component (see Appendix A,
paragraph A.2) using the thickness from STEP 2. (as per
A2.2)
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LEVEL 1
- STEP 8
From STEP 4
Rt = 0.33 0.33
= 0.212
ACCEPTABLE
Else use
0.212
(5.14)
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0.334
RSF 0.904
1 1 / 1.056 * (1 0.334)
Mt comes from Table 5.2
If RSF RSFa , then the region of local metal loss is acceptable for
operation at the MAWP determined in STEP 7.
If a RSF < RSF , then the region of local metal loss is acceptable for
operation at MAWPr, where MAWPr is computed using the equations in
Part 2, paragraph 2.4.2.2. The MAWP from STEP 7 shall be used in this
calculation.
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Folias
Factor
Mt
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25
20
Series1
15
10
0
1 2 3 4 5
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c 9 0.094 9 TRUE
0.7 EL 1.0
0.7 0.85 1.0 TRUE
0.7 Ec 1.0
0.7 0.85 1.0 TRUE
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STEP 9.3
Determine the Tensile Stress Factor
Ec 4 3E L 0.85 4 3 0.85
2 2
TSF 1 1 1.467
2 RSF EL 2 0.914
0.85
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STEP 9.4
Determine the screening curve
in Figure 5.8 based on TSF.
Enter Figure 5.8 with the
calculated values of c and R t
.
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LEVEL 2 - STEPS 1 TO 7
STEPS 1 thru 7 same as LEVEL 1
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LEVEL 2 STEP 8
30 29.21
29.21 29.21
28
22.86 STEP 8
26
Determine the
20.574 Remaining
24 Strength Factor
22.86
22 19.05 for the
20.574
Longitudinal
20
17.78 CTP rank the
19.05
18
readings in order
17.78
16.51 16.51
16 15.748
14 15.748
12
11.43 11.43
10
1 2 3 4 5 6 7 8 9
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STEP 8
STEP 8.2
Set the initial evaluation starting point as the location of
maximum metal loss,
this is the location in the thickness profile where t mm is recorded.
Subsequent starting points should be in accordance with
the ranking in STEP 8.1.
STEP 8.3
At the current evaluation starting point, subdivide the
thickness profile into a series of subsections.
The number and extent of the subsections should be
chosen based on the desired accuracy and should
encompass the variations in metal loss.
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Level 2 STEP 9
STEP 9 Evaluate the longitudinal extent of the flaw for
cylindrical and conical shells, the larger of the circumferential
and meridional extent (whichever is bigger) for spherical shells
and formed heads.
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Level 2 STEP 10
STEP 10 For cylindrical shells, conical shells, and
elbows, evaluate the circumferential extent of the
flaw using the following criteria.
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EXERCISE 2
Pressure vessel
Design pressure/Temperature = 2085kPa/115oC
Inside diameter/Wall Thickness = 2285mm/20mm
Corrosion allowance = 3.5mm
Material = SA 516 Grade 70
Weld joint efficiency = 1.0
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EXERCISE 2
The vessel has a Local Thin Area with the following dimensions
Is this condition acceptable?
Longitudinal readings taken at 10mm intervals
Circumferential readings at 5mm intervals
A516 70 1986 37.778 65.556 93.333 121.11 148.89 204.44 260 315.56 343.33 371.11 398.89 426.7 454.4 482.2 510 537.78
120663 120663 120663 120663 120663 120663 120663 120663 120663 114457 102046 82740 64124 44818 31028 17238
C1 C2 C3 C4 C5 C6 C7 C8 C9
M1 20 20 20 20 20 20 20 20 20
M6 20 20 20 20 20 20 20 20 20
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ASSESSMENT OF PITTING
CORROSION
Pitting results in weeping leakage, rarely in rupture (burst).
The risk is that they would propagate into cracks.
Products of corrosion tend to be acidic inside the pit and
therefore the pits could have different rates of growth.
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ASSESSMENT OF PITTING
CORROSION
There are pitting rules in API 510, but if they are not met there
is no way of rerating in API 510, while API 579 will give re-
rating rules.
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Assessment of Pitting
Level 1
Based on typical pitting charts
Level 2
Methods provided based on ligament efficiency
Pit couples evaluated
Consider at least ten pit-couples
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Level 2
Thickness partitioned into pitted thickness based on average
pit depth, and remaining thickness
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Level 2
Orientation of pits relative to direction of stress can be
considered
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Level 1 Assessment
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Level 1 Limitations
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Level 2 Limitations
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Level 1 Assessment
Pit charts & max pit depth
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STEP 1
Determine the following parameters:
Di , FCA, trd and RSFa
Where
Di is the inside diameter of the cylinder, cone (at the location
of the flaw), sphere, or formed head
FCA is Future Corrosion Allowance
trd is the uniform thickness away from the pitted region
established by thickness measurements at the time of the
assessment.
RSFa is the allowable remaining strength factor
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STEP 2
Determine the wall thickness to be used in the assessment
using Equation (6.1). If thickness readings are available, this
wall thickness may be determined using Equation (6.2).
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Step 3
Locate the area on the component that has the highest density
of pitting damage based on the number of pits.
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STEP 4
Determine the maximum pit depth, wmax , in the
region of pitting damage being evaluated.
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STEP 5
Determine the ratio of the remaining wall thickness to the
future wall thickness in the pitted region using Equation (6.3).
(6.3)
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STEP 7
Compare the surface damage from the photographs or
rubbings to the standard pit charts shown in Figures 6.3
through 6.10. Select a pit chart that has a measure of surface
damage that approximates the actual damage on the
component.
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STEP 8
Determine the RSF from the table shown at the bottom of the
pit chart that was chosen in STEP 6 using the value of Rwt
calculated in STEP 5.
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STEP 9
If RSF RSFa , then the pitting damage is acceptable for
operation at the MAWP determined in STEP 2.
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Pitting
Level 2 LTA within Pitting
Widespread Localised
within a pitting
Pitting LTA
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LEVEL 2 - STEP 1
Step 1 - Determine parameters
20 w.t. 0.25 pipeline API 5L X60 ERW
P = 1000 psi
D = inside diameter of pipeline 20-2 x 0.25 = 19.5
FCA = 0
RSFa = 0.90
t = 0.25
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LEVEL 2 STEP 2
= 0.25 0 = 0.25
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LEVEL 2 STEP 3
Pit size and distance
dik = diameter of pit i in pit-couple k
djk = diameter of pit j in pit-couple k
Pk = pit-couple spacing (pitch) of pit-couple k
wik = depth of pit i in pit-couple k
wjk = depth of pit j in pit-couple k
For a detailed analysis consider the angle k
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LEVEL 2 - STEPS 4
Determine the depth of each pit below trd in all pit-couples, , wi k
and , wj k (see Figure 6.11.b) and compute the average pit
depth, wavg , considering all readings.
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STEP 5
Calculate the components of the membrane stress field, 1
and 2 (see Figure 6.11). Membrane stress equations for
shell components are included in Appendix A.
(A11)
(A17)
Appendix A. A.3
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STEP 6
Determine the MAWP for the component (see Appendix
A, paragraph A.2) using the thickness from STEP 2
For B31.8 pipe:
PD
t
2S S = FET Sy
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STEP 7
For pit-couple k ,
calculate the
Remaining
Strength Factor:
Single Layer
Analysis This
analysis can be
used when the
pitting occurs on
one side of the
component.
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STEP 7
For pit-couple k ,
calculate the
Remaining Strength
Factor:
Multiple Layer Analysis
This analysis is used to
account for pitting on
both sides of the
component (see Figure
6.15).
number of layers, N , is
based on the depth of
pits on both sides of the
component
NOT overlapped for L2
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STEP 8
Repeat STEP 7 for all pit-couples, n , recorded at the time of
the inspection.
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STEP 9
Evaluate results based on the type of pitting damage
1) Widespread Pitting For widespread pitting that
occurs over a significant region of the component, if
RSFpit RSFa , then the pitting damage is acceptable
for operation at the MAWP determined in STEP 6
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STEP 10
Check the recommended limitations on the
individual pit dimensions:
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EXERCISE - PITTING
OD pits discovered during the excavation of a 20 pipeline.
Away from the pitting the pipe wall is 13.5mm
FCA -> 2.0mm
RSFa -> 0.9
Max pit depth -> 4.5mm
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Use RSFa=0.9
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EXERCISE - PITTING
P = 700 psi @ 70oF
API 5L X40 20 w.t. 0.25, ERW
Two pit couples
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SCOPE
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CAUSE OF H BLISTERS
Accumulation of H at
imperfections such as laminations
and inclusions, and in banded
microstructures. H combines into
H2 which slows down diffusion.
Lamination =
unfused plane in plate.
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Blisters
Closely spaced blisters combined
based on LTA rules, and
distance between two adjacent blisters < 2tnom
Blisters generally drilled, if not already cracked, to
relieve accumulation of pressure
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APPLICABILITY
Operating temperature 205oC or less.
Material ductile, not embrittled.
No cyclic service.
Physical bulging observed visually or by UT.
Internal pressure is only significant load.
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Level 1
Blisters are accepted based on
Diameter
`<50.8mm (2 inch) and blister is vented or unvented or
diameter< 0.6(Dtnom)1/2 and blister is vented
blister projection < 10% blister diameter
tmm for unbulged side is > 50% tnom
no periphery cracks towards inside or outside surface
distance to weld seam >25mm (1 inch)
distance from major structural discontinuity > 1.8(Dtnom)1/2
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Level 2
Permits consideration of blisters that exceeds limits of Level 1
as LTAs Permits consideration of peripheral cracking
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MULTIPLE BLISTERS
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LEVEL 1
Step - 1. Assemble the following
information
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LEVEL 1 - BLISTER
Step - 2. Blisters are acceptable, without repair, if
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LEVEL 2 - BLISTER
STEP 1.
Same as level 1.
STEP 2
Determine the wall thickness to be used in the
assessment
STEP 3
Distance between the edge of the Blister
damage and the nearest discontinuity
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STEP 5
If the Blister has periphery cracks on the
opposite side from the bulging, then the blister
does not pass the Level 2 assessment.
If the periphery cracks are on the same side as
the bulging, then proceed to STEP 9.
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STEP 7
If the blister projection above the surface satisfies
Equation (7.13), then proceed to STEP 8. Otherwise,
proceed to STEP 9.
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STEP 9
Evaluate as LTA
STEP 10
If go to STEP 12
Else go to STEP 11
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STEP 12
The Level 2 Assessment is complete, the component may
be returned to service.
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EXERCISE
Pressure vessel data: Blister A
diameter s = 254mm
MAWP = 1725kPa at
dimension c = 203mm
175oC
Lb = 457mm
ID = 2438mm
bulge external
tnom = 29mm
blister projection BP = 38mm
No metal loss remaining thickness tmm = 18mm
FCA = 3.175mm no cracks
Material SA 516 Gr.70 length of crown cracks sC = 150mm
Allowable stress = spacing to nearest weld Lw = 254mm
120658kPa spacing to structural discontinuity =
Weld joint efficiency = 650mm
0.85
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EXERCISE
Blister A
diameter s = 254mm
dimension c = 203mm
Lb = 457mm
bulge external
blister projection BP = 38mm
remaining thickness tmm = 18mm
no cracks
length of crown cracks sC = 150mm
spacing to nearest weld Lw = 254mm
spacing to structural discontinuity = 650mm
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EXERCISE
Blister C
diameter s = 150mm
dimension c = 150mm
Lb = 300mm
bulge external
blister projection BP = 15mm
remaining thickness tmm = 15mm
no cracks
length of crown cracks sC = 50mm
spacing to nearest weld Lw = 150mm
spacing to structural discontinuity = 750mm
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HIC Damage
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Level 1 STEP 3
STEP 3 If all of the following requirements are
satisfied, then proceed to STEP 4.
The planar dimensions of the HIC damage satisfy:
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Step 3 contd
The HIC damage is not surface breaking
The distance between the edge of the HIC damage and the
nearest weld seam
The distance from the edge of the HIC damage to the nearest
major structural discontinuity satisfies
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Software
VCESage
CodeCalc
ENG-Fit
262 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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VCESage - Pitting
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VCESage - LTA
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ENG-Fit TWI
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SCOPE
General shell distortion
shape variation and flat spots.
Out-of-Roundness
Difference in diameter.
Bulge
Inward or outward.
Dent
Small local radius or notch.
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LEVEL 1
Fabrication tolerance of applicable construction code.
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LEVEL 1
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Level 2 Limitations
The component geometry must be one of the
following:
1. Flat plate
2. Pressure vessel cylindrical or conical shell section
3. Spherical pressure vessel
4. Straight section of a piping system
5. Elbow or pipe bend that does not have structural
attachments
6. Shell course of an atmospheric storage tank
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EXERCISE - PEAKING
LEVEL 2
Step 1
Pipe OD = 36
Wall t = 0.5
R = 17.75 inside radius
Material = 1-1/4Cr 1/2Mo ASTM A691 Class 41
E = 25.5 106 psi
= 0.3 Poisson ratio
Design Pressure = 315 psi
Design temperature = 800oF
Sa = 16800 psi allowable stress at 800oF
Joint efficiency = 100%
FCA = 0.05
Peaking distortion = 0.31
Hf = 3.0 the induced stress is secondary
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Out of Roundness/Peaking
Cf CHART PEAKING
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Weld Misalignment
Peaking Level 2
STEP 2
Determine thickness to be used in the
assessment
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Weld Misalignment
Peaking Level 2 contd
STEP 3
P R FCA
0.6
Membrane stress E t FCA
m
315psi 17.75"0.05"
0.6 12579psi
1 0.5"0.05"
STEP 4
Ratio induced bending / applied membrane
12(1 )PR 2 3
S
E( t FCA )
P 3
0.5 0.05
3
2
2.81
(25.5 10 )(0.5 0.05) 6 3
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PEAKING LEVEL 2 -
STEP 3
Step 4 - continues
0.31
0.0175
R 17.75 0.05
Figure 8.16 SP = 2.81 and /R = 0.0175 Cf = 0.83
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PEAKING LEVEL 2 -
STEP 4
Step 6
Compare RSF to allowable RSFa = 0.90
In this case, OK.
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Step 1
Evaluate peaking at 315 psi without cycling.
Done. OK
Step 2
Determine the total stress range (Appendix F)
circumferential = 1 = 12579 psi + 12579 x 3.43
= 55725 psi
Longitudinal = 2 = 1 / 2 = 6290 psi ~ 0
Radial = 3 = 0
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OVALITY
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OVALITY - LEVEL 1
Vessel deformed after repair post-weld heat treatment.
Design condition = 500 psi at 650oF
Wall thickness = 1.875
Inside diameter = 120
Material = SA 516 Grade 70
Joint efficiency = 100%
FCA = 0.125
Measured:
Dmax = 120.5
Dmin = 119.4
OVALITY - LEVEL 2 -
STEP 1
Step 1: collect data
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500psi 60 0.125
0.6 17479psi
1.0 1.875 0.125
1.5( D D ) cos 2
or
R m ax m in
P (1 )
b 2 3
D
( t FCA )
1 C
t FCA
m
S
E
0.593
500psi(1 0.3 ) 122 2
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Step 4
H S 3 17500psi
RSF f a
1.0
(1 R 17479psi(1 0.593)
or
m b
)
Step 5
OK
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EXERCISE - OVALITY
Evaluate the effect of 6% ovality on an API 5L X60,
20 OD x 0.5 wall gas pipeline operating at 70oF
and 1000 psi in a populated area (0.4 location class
factor).
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CRACK IN-SERVICE
CORROSION (ENVIRONMENTAL EFFECT)
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CRACK IN-SERVICE
3RD PARTY DAMAGE
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INTRODUCTION TO
FRACTURE MECHANICS
Fracture mechanics: Sensitivity of structures
(equipment, airplane fuselage, pressure vessels,
pipelines, etc.) to cracks.
K < KC
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WHY IS IT IMPORTANT?
You have a vessel or pipeline in service, it develops cracks
30% through-wall. Should you shutdown? Immediately?
Should you repair or replace? Will it continue to grow?
You just installed a new vessel or pipeline, and find out that
the welds are not fully penetrated, or that there are weld
cracks missed by earlier radiography. What can you do?
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STRESS INTENSITY
The stress intensity is a parameter of the general
form
K ( I
a ) F
= nominal stress, as if there is no crack, ksi
a = a measure of the crack size, in
F = a factor that depends on the crack shape and the component
shape
KI = stress intensity factor for crack opening in mode I, ksi(in) 0.5
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5(CVN )
K IC
S y
0.25
S y
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EXERCISE
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LEVEL 1
Step - 1. Determine MAWP (design pressure, MAOP), and temperature, and operating
loads.
MAWP = 3450kPa
T = 21oC
Material is PWHT
Determine the applicable figure, for example cylinder with longitudinal joint and crack
parallel to joint
Solid = t/4 flaw, Dashed = t flaw.
A allowable flaw size in base metal no PWHT
B allowable flaw size in weld metal with PWHT
C Allowable flaw size in weld no PWHT
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LEVEL 1
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LEVEL 1
Step - 4. Determine the screening curve from the step-3 figure.
Solid curve (assume crack is t/4)
Curve A (base metal).
Step - 5. Knowing the wall thickness and material, determine Tref (MAT PART
3).
Tref for 12mm wall carbon steel curve B section 3 = -23oC
Step - 6. Calculate T - Tref + 55.6oC, and enter Figure 9.13. Read the
permitted crack length 2c.
T - Tref + 55.6oC = 70 -(-10) + 100 = 180oF
2c permitted = 203mm
Step - 7. Compare the measured crack length (step-2) to the permitted crack
length (step-6).
Actual crack is 150mm < permitted 203mm OK
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EXERCISE - LEVEL 1
Longitudinal crack close to weld of carbon steel
pipeline.
No PWHT.
Crack is 160mm long.
Crack is 30% through wall.
T = 20oC.
Base material is SA-516 55 normalised
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LEVEL 2
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LEVEL 2 - STEP 1
Step - 1. Determine operating and design loads (pressure,
temperature, external loads).
Pipeline
OD = 24
t = 0.5
API 5L X52 SY = 52 ksi yield stress
P = 1200 psi at 50oF
Soil settlement = 1 over 100 ft
360o crack around girth weld, at OD, 20% penetrated
Penetration (a) = 20% x 0.5 = 0.10
SY* = flow stress ~ SY + 10 ksi = 62 ksi
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LEVEL 2 - STEP 2
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LEVEL 2 - STEP 2
Primary bending stress through-wall
PD 1200 24
m 14.4ksi
prim ary
4t 4 0.5
Secondary bending stress at OD
8ED 8 (30 10 ) 24 1 6
4ksi
sec ondary
b 2 2
L (1200)
Residual stress at crack (Appendix E)
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LEVEL 2 - STEP 3
Step - 3. Determine the material properties
Yield SY (actual or mean) = 52 ksi
Tensile SU (actual or mean) = 90 ksi
Fracture toughness KIC (mean)
Appendix F - Curve B
t = 0.5
Tref = - 10oF
T = 50oF
T - Tref = 60oF
LEVEL 2 - STEP 4
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LEVEL 2 - STEP 5
Step - 5. Apply the partial safety factors
Pm = Pm PSFS
Pb = Pb PSFS
Material Toughness
Flaw Size
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LEVEL 2 - PARTIAL
SAFETY FACTORS
If the crack is shallow (less than 0.2 in deep).
If the stress is well known (COV = 0.10).
If an acceptable probability of failure (pf) is 10-3
If the failure can be either fracture or plastic
collapse (Rky < Rc)
Then
PSFS = 1.40 = 1.40 calculated
PSFk = 1.43 KIC = 100 / 1.43 = 70 ksi(in)0.5
PSFa = 1.20 a = 1.2 x 20%t
= 1.2 x 0.2 x 0.5 = 0.12
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LEVEL 2 - STEP 6
3
1
Z
2 2 y xy
1 x
2y
a
x
t
t
y
R
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LEVEL 2 - STEP 6
a 0.12"
x 0.24
t 0.50"
t 0.5"
y 0.04
R 12"
1
Z 1.3
2 2 0.04 0.24 0.04
1 0.24
2 0.04
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LEVEL 2 - STEP 7
Step - 7. Calculate the ratio Lrp
P
26.2
ref 0.50
p
Lr
SY 52
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LEVEL 2 - STEP 8
Step - 8. Compute the stress intensity attributed to
the primary load Kip (Appendix C), using the
factored stress.
ri a
a F(
P
KI ; )
ro t
ri 11.5"
0.96
ro 12"
ro 12"
1.04
ri 11.5"
a 0.12"
0.24
t 0.50"
1 0.24
0.43
1 1.04
a r
( 0.24; i 0.96) 0.43F 0.65
t ro
F 1.5
a F (1.4 14.4 ksi ) 0.12" 1.5 18.6 ksi
P
KI in
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LEVEL 2 - STEP 9
Step - 9. Compute the reference stress for secondary and residual stresses
refSR (Appendix D).
LEVEL 2 - STEP 9
35 352 9 (3 57.4) 2
ref 184ksi SY 52ksi
SR
184
3.5
S
Lr
52
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LEVEL 2 - STEP 10
Step - 10. Compute the secondary and residual stress reduction
factor
If refRS > SY
26.2
P
If refRS < SY
Srf = 1.0
LEVEL 2 - STEP 10
Step - 10. Compute the stress intensity due
to secondary and residual stresses KISR.
a 0.12"
0.24
t 0.50"
a
1
t 1 0.24
0.44
r 1 1.04
2 2
1
o
r i
r 11.5
i
0.96
ro
12
a r
0.24; 0.96 0.44 F 0.65
i
t r o
F 1.48
66 ksi 0.12" 1.48 60 ksi
SR
K I
in
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LEVEL 2 - STEP 11
Step - 11. Compute the plasticity interaction factor .
2
K I SR
1 1 60
2
aeff a 0.12"
2
SY
2 1 52
aeff 0.33"
aeff 0.33
o 1.66
a 0.12
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LEVEL 2 - STEP 12
K I 18.6 2 60
P SR
KI
Kr 1.98
K IC 70
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FAILURE ASSESSMENT
DIAGRAM
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COA = 2C2 / E
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Flaw length
2C = 6 x depth = 6 x wall = 6 x 0.63 = 3.78
C = 1.89
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LEAK RATE
Leak rate of incompressible fluid (liquid) through orifice
q = Cd A ( 2g 144 P / )0.5
P = 747 psi
= 62.4 lb/ft3
g = 32.2 ft/sec2
Cd = 0.61
A = COA = 0.031 in2 = 2.15 10-4 ft2
EXERCISE
A pipeline has a long ID
crack along a longitudinal
seam.
API 5L X40
D = 30, t = 0.25
Crack depth = 0.10
Is it safe to operate at 400 psi
and 100oF?
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Level 1 Assessment
Limitations:
No fire damage or overheating event resulting in a significant
change in shape (e.g. sagging or bulging) or excessive metal
loss from scaling.
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Level 1 Assessment
Limitations contd:
material meets or
exceeds the respective
minimum hardness and
carbon content
(Table 10.1)
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Level 2
Limitations:
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Level 3
Use Level 3 assessment if the following apply:
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Level 1 Assessment
(component subject to a single design condition )
STEP 1
Determine the maximum operating temperature, pressure, and
service time the component is exposed to.
If the component contains a weld joint that is loaded in the stress
direction that governs the minimum required wall thickness
calculation, then 13.9 C (25 F) shall be added to the maximum
operating temperature to determine the assessment
temperature.
Otherwise, the assessment temperature is the operating
temperature. The service time shall include past and future
planned operation.
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Level 1 Assessment
(component subject to a single design condition )
STEP 2
Determine the nominal stress of the component for the operating
condition defined in STEP 1 using Appendix A.
The computed nominal stress shall include the effects of service-induced
wall thinning.
e.g. for a boiler tube
Where:
e is a parameter used for computing the boiler tube thickness
Dc= D+2( LOSS+FCA)
D = tube inside diameter
P is the internal design pressure.
tc = nominal thickness LOSS - FCA
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Level 1 Assessment
(component subject to a single design condition )
) STEP 3
Determine the material of
construction for the
component and find the
figure with the screening
and damage curves to be
used for the Level 1
assessment from Figures
10.3 through 10.25.
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Level 1 Assessment
(component subject to a single design condition )
STEP 4
Determine the maximum permissible time for operation based on
the screening curve obtained from STEP 3, the nominal stress
from STEP 2, and the assessment temperature from STEP 1.
If the time determined from the screening curve exceeds the
service time for the component from STEP 1, then the
component is acceptable per the Level 1 Assessment procedure.
Otherwise, go to STEP 5.
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Level 1 Assessment
(component subject to a single design condition )
STEP 5
Determine the creep damage rate,
Rc and associated creep damage
Dc for the operating condition
defined in STEP 1 using the
damage curve obtained from STEP
3, the nominal stress from STEP 2,
and the assessment temperature
from STEP 1.
The creep damage for this
operating condition shall be
computed using Equation (10.4)
where the service exposure time is
determined from STEP 1.
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Level 1 Assessment
(component subject to a single design condition )
STEP 6
If the total creep damage determined from STEP 5 satisfies
Equation (10.5), then the component is acceptable per the Level
1 Assessment procedure.
Otherwise, the component is not acceptable and the
requirements of paragraph 10.4.2.3 shall be followed.
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Case History 1
Cracked ring-joint flange.
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Case History 2
Severe out-of-roundness of a new pressure vessel.
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Case history 3
Fire-damaged vessel.
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Case History 4
Creep life assessment of a refinery pressure vessel.
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FIRE DAMAGE
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FIRE DAMAGE
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Fire Damage
Methods provided to determine fire zone (maximum
temperature)
Level 1 acceptance based on fire zone, depending on
material of construction
Level 2 acceptance based on evaluation of fire exposed
material properties
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APPLICABILITY
Vessel, piping and tank condition following a fire: should it be used-as-is?
repaired? replaced?
For floating tank roofs and tank bottom, also refer to API 653.
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REQUIRED DATA
Type of fuel (estimate of fire temperature).
Location of ignition source.
Plot plan of affected areas.
Wind direction.
Time at temperature.
Cooling rate.
Fire fighting agent (sea/water/river/tank water).
Estimate of cooling rate.
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ZONE III
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ZONE IV
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ZONE V
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ZONE VI
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REPAIR REPLACEMENT
DECISIONS
Zone I
No damage.
Zone II
Insulation, insulation jackets.
Electronics.
Plastics,PVC.
Zone III
Gaskets (non-metallic).
Valve trims.
Belts.
Non-metallics.
Electrical, electronic.
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REPAIR REPLACEMENT
DECISIONS
Zone IV
Motors.
Valve springs.
Rupture disks.
Roll joints (HX).
Sag tubing.
Aluminum equipment.
Zone V
All small equipment replaced.
All copper replaced.
All non-metallic goods replaced.
Clean, inspect and pressure test major equipment.
Replace B7 bolts.
Replace sensitized SS.
Replaced distorded supports.
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REPAIR REPLACEMENT
DECISIONS
Zone VI
Replace all.
Some fire protected equipment may be
inspected, pressure tested, and still used.
Areas exposed to molten metal experience
cracking.
Change in grain size, hardness, mechanical and
corrosion resistance properties.
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LEVEL I
Carbon steel: IV
Low alloy steel: IV
Austenitic SS: IV
Alloy 20: IV
Alloy 400: III
Duplex SS: II
Alloy 800: IV
Alloy 600: IV
Copper alloys: II
Aluminum alloys: II
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LEVEL II
Step 1. Measure hardness and
convert to ultimate strength.
Brinell (3000kg) Vickers Su (ksi)
190 200 90
143 150 70
124 130 60
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LEVEL II
Determine the allowable stress
Reduce the MAWP for thinning, blisters, laminations, shell distortion, cracks.
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EXERCISE
A horizontal vessel.
ID = 150
Thickness = 9/16
Length = 35 ft
2:1 elliptical head.
Material SA 516 Gr. 70 carbon steel.
Not stress relieved.
Contains heavy oil.
Epoxy phenolic outer coating.
No insulation.
MAWP = 80 psig at 650oF
E =0.85
FCA = 1/16
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EXERCISE
Fire damage:
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PART 12
ASSESSMENT OF DENTS,
GOUGES, AND DENT-
GOUGE COMBINATIONS
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Dents or Gouges?
a) Dent An inward or outward
deviation of a cross-section of a shell
member from an ideal shell geometry
that is characterized by a small local
radius or notch.
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Limitations
Must have sufficient toughness
Consider the damage may result in cold work
Damage is to inward
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Overview of dent-gouge
combinations
Level 1 Assessment limited to dent-gouge combinations in carbon
steel cylindrical shells located away from structural discontinuities. A
screening curve is provided to determine the acceptability for
continued operation based on the ratio of the dent depth to cylinder
outside diameter and the ratio of the gouge depth to wall thickness.
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Dent-Gouge Assessment
Level 1
STEP 1
Collect the data
Dent Depth in the Pressurized Condition, ddp , and
Unpressurized Condition, dd0.
Gouge Depth dg
Minimum Specified Yield Strength, ys
Minimum Specified Ultimate Tensile Strength, uts
Cyclic Pressure Components, Pmax and Pmin.
Dent-gouge Combination Spacing to Weld Joints, Lw.
Dent-gouge Combination Spacing to Major Structural
Discontinuities, Lmsd
Additional data includes D, FCA , either trd or tnom, and
LOSS
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Level 1 contd
Determine thickness and gouge depth to be used in the
assessment
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Level 1 contd
STEP 4
Determine Hoop Stress
STEP 5
Determine the gouge depth to wall thickness ratio, d gc/tc , and the
dent depth to component diameter ratio, ddp/D. Enter these data
with the circumferential stress, Cm , determined in STEP 4 on
Figure 12.4. If the point defined by the intersection of these
values is on or below the curve in this figure that corresponds to
the circumferential stress in terms of the minimum specified yield
strength for the component and the component is not in cyclic
service, proceed to STEP 6. Otherwise, the Level 1 Assessment
is not satisfied.
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Level 1 STEP 5
Figure 12.4
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Level 1 - STEP 6
STEP 6
Determine the MAWP for the component (see Annex A,
paragraph A.2) using the thickness from STEP 2. If the
MAWP is greater than or equal to the current design
condition, then the component is acceptable for continued
operation.
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PART 13
Laminations
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Definition
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Overview of Level 1
Assessment
The Level 1 Assessment procedure is a screening criterion for
laminations based on: the lamination size, orientation and spacing to
weld joints, structural discontinuities, and other laminations.
If there are two or more laminations that are closely spaced at different
depths in the wall thickness of the component, then the group of
laminations are evaluated as equivalent HIC damage using the Level 1
assessment procedures in Part 7.
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Level 1 Assessment
STEP 1
Check for surface bulging. If so, evaluate as a blister
Step 2
Determine:
a) Lamination Dimensions, s and c.
b) Lamination Height Lh ,.
c) Lamination-to-Lamination Spacing, Ls
d) Lamination Minimum Measured Wall Thickness, t mm
e) Lamination Spacing To Weld Joints, Lw.
f) Lamination Spacing To Major Structural Discontinuities, L msd .
g) Lamination Cracking
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Level 1 STEP 3
STEP 3
If > 1 lamination
AND no through thickness cracking
AND
Treat as one lamination
If > 1 lamination
AND at different depths
AND NOT
Treat as HIC
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Level 1 STEP 4
STEP 4
If Lh 0.09 . Max [s, c]
Go to STEP 5
Else evaluate Lh as a crack.
STEP 5
Determine thickness to be used in the
assessment
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Level 1 STEP 6
STEP 6
Check the following:
No indication of through thickness cracking
Not surface breaking
Distance to nearest weld seam
Distance to MSD
If hydrogen charging:
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Level 1 STEP 7
STEP 7
Determine the MAWP for the component using the
thickness from STEP 5. The component with the
lamination is acceptable for operation at this calculated
MAWP.
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Lamination Level 2
Essentially the same as Level 1
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The Test
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GOOD LUCK
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