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API 579-1/ASME FFS-1 (2007)

API 579-1/ASME FFS-1


Fitness for Service
of Piping, Vessels and Tanks

1 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Daily Schedule

08:30 10:00 1st Session


10:00 1045 Coffee Break
10:45 12:30 2nd Session
12:30 13:30 Lunch
13:30 15:00 3rd Session
15:00 15:45 Coffee Break
15:45 17:00 Open session

In order to ensure the smooth running of the Seminar, it is extremely important


that daily timings are strictly adhered to.

2 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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pt 1
API 579-1/ASME FFS-1 (2007)

PROGRAMME OBJECTIVES
Understand FFS for static, mechanical equipment

Balanced fundamental technical principles with a practical application


to field conditions

See how ASME codes apply to FFS

Use ASME and API rules to assess remaining life

Apply practical examples to analyze conditions

Apply the step-by-step 3-level approach

Understand risk-based evaluation of remaining life.

Evaluate structural integrity and assess remaining life.

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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

DAY 3 PITTING & CORROSION


PART 8 Weld Misalignment & Shell Distortions
PART 9 Cracks & Crack-Like Flaws
PART 10 Creep
PART 11 Fire Damage

DAY 4 FIRE & MECHANICAL DAMAGE

PART 12 Dents & Gouges


PART 13 Laminations
Overview & Wrap Up

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pt 2
API 579-1/ASME FFS-1 (2007)

Ron Frend - Profile


Ronald Frend M.Sc.
Shell Tankers (UK) Ltd
1970 1984
Marine Engineer Certified Chief Engineer
Petroleum Development (Oman)
1984 1989
Mechanical Equipment Supervisor
Head of Maintenance Planning
Head of Surface Support (North Oman)
Private Consultant
1989 present
Petro-Chem, Manufacturing, Shipping, Process

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API 579-1/ASME FFS-1


A Joint API/ASME Standard
for the evaluation of the
Fitness of Equipment to
remain in service while
suffering various types of
damage or code violation.

This standard is based on

STRENGTH
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API 579-1/ASME FFS-1 (2007)

What is FFS?
ASME and API codes for pressurized equipment do not
address in-service equipment degradation nor deficiencies in
original fabrication.

These codes do not permit crack-like flaws, have empirical


rules used for acceptance of metal loss, and provide
minimum guidance on the acceptability of other flaws and
damage types (for example, blisters, creep, and fire damage).

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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.

The product of an FFS assessment is a decision to operate the


equipment as is, or to alter, repair, monitor, or replace the
equipment.

API 579-1/ASME FFS-1 also provides guidance on appropriate


inspection intervals.

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API 579-1/ASME FFS-1 (2007)

API 579-1/ASME FFS-1 FFS


API 579-1/ASME FFS-1 supplements the
requirements in API 510, API 570, and API 653.

API 579 has three functions:

1. To ensure safety of plant personnel and the public while


older equipment continues to operate.
2. To provide technically sound FFS assessment procedures
to ensure that different service providers furnish consistent
life predictions.
3. To help optimize maintenance and operation of existing
facilities to maintain availability of older plants and
enhance long-term economic viability.

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Continue In Service?
The following questions are frequently asked regarding the
mechanical integrity of the equipment in question:

"Can this equipment be put back in service without repair?"

"How long can this equipment be kept in service?"

"Can the repair work be deferred to the next scheduled turnaround


maintenance time?"

"What would be the consequence when the damage propagates if not


repaired?"

"What would be the most effective way to detect and monitor the
damage?"

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API 579-1/ASME FFS-1 (2007)

FFS assessments

can be used at any stage of


the life of a structure:
In the concept and design
phase, material property
requirements can be set.

In the construction phase

During routine inspection.

Towards the end of the design


life of a structure.

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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.

Such FFS analyses typically involve


stress analysis,
fracture mechanics,
material testing and
quantitative NDT measurements, in addition to
the operating conditions.

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API 579-1/ASME FFS-1 (2007)

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

ASME forms Post Construction Committee (PCC) to develop standards


for in-service fixed equipment

API and ASME agreed to form a joint committee to produce a single


FFS standard that can be used for pressure-containing equipment for
all industries published in 2007.

CRE Committee on Refinery Equipment

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API 579-1/ASME FFS-1 (2007)

New Joint API and ASME FFS Standard

API 579 forms basis of joint API/ASME standard produced by the


API/ASME joint committee

API 579-1/ASME FFS-1 2007 supersedes API 579-2000

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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Overview of API 579-1/ASME FFS-1


Sections have been renamed to Parts and
Appendices to Annexes

New Enhancements Existing Sections and New Parts


Part 5 - Assessment of Local Thin Areas, assessment procedures for
gouges have been relocated to Part 12
Part 7 - Assessment of Blisters and HIC/SOHIC Damage, assessment
procedures for HIC/SOHIC damage have been added
Part 8 - Assessment of Weld Misalignment and Bulges, assessment
procedures for bulges removed, assessment procedures for dents,
gouges, and dent-gouge combinations have been relocated to Part 12
Part 10 - Assessment of Equipment Operating in the Creep Range,
assessment procedures for remaining life calculations for components
with or without crack-like flaws have been added
Part 12 - Assessment of Dents, Gouges, and Dent-Gouge Combinations,
new Part
Part 13 - Assessment of Laminations, new Part
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API 579-1/ASME FFS-1 (2007)

Overview of API 579-1/ASME FFS-1


New Enhancements Existing and New Annexes
Annex B - Stress Analysis Overview for a FFS Assessment, complete
rewrite to incorporate new elastic-plastic analysis methods and fatigue
evaluation technology developed for the ASME Div 2 Re-write Project,
Structural Stress/Master S-N Approach will be included
Annex C - Compendium of Stress Intensity Factor Solutions, new stress
intensity factor solutions for thick wall cylinders, through wall cracks in
cylinders and spheres, holes in plates
Annex E - Compendium of Residual Stress Solutions, complete rewrite to
incorporate new solutions developed by PVRC Joint Industry Project
Annex F - Material Properties for a FFS Assessment, new stress-strain
curve model incorporated
Annex H - Technical Basis and Validation of FFS Procedures
Annex K - Crack Opening Areas, new annex covering crack opening areas
for through-wall flaws in cylinders and spheres

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Overview of API 579-1/ASME FFS-1


Organization of Parts
Part 1 Introduction
Part 2 FFS Engineering Evaluation Procedure
Part 3 Assessment of Equipment for Brittle Fracture
Part 4 Assessment of General Metal Loss (tm < tmin - large area)
Part 5 Assessment of Localized Metal Loss (tm < tmin - small area)
Part 6 Assessment of Pitting Corrosion
Part 7 Assessment Of Hydrogen Blisters and Hydrogen Damage Associated
with HIC and SOHIC
Part 8 Assessment of Weld Misalignment and Shell Distortions
Part 9 Assessment of Crack-Like Flaws
Part 10 Assessment of Equipment Operating in the Creep Regime
Part 11 Assessment of Fire Damage
Part 12 Assessment of Dents, Gouges, and Dent-Gouge Combinations
Part 13 Assessment of Laminations
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pt 9
API 579-1/ASME FFS-1 (2007)

Overview of API 579-1/ASME FFS-1

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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API 579-1/ASME FFS-1


Covers equipment constructed to
ASME B&PV Section VIII, Div 1
ASME B&PV Section VIII, Div 2
B31.3, Process Piping
B31.1, Power Piping
API 650
API 620

It can also be used with equipment constructed


to other recognized standards

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API 579-1/ASME FFS-1 (2007)

FFS Methods
Based on a variety of the American and British codes and
standards, such as

ASME Pressure Vessel and Boiler Code Section XI,


ASME/ANSI B31.G, Modified B31.G (also known as
"RSTRENG" method),
BSI PD 6493 (now BS 7910) and
API 579-1/ASME FFS-1

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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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API 579-1/ASME FFS-1 (2007)

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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In-service damage mechanisms

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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API 579-1/ASME FFS-1 (2007)

Damage Mechanisms
Regardless what materials in what process
conditions, the symptoms of corrosion damage
normally exhibit in the following forms:

Uniform metal loss or wall thinning due to general attack;


Local wall thinning due to localized attack;
Surface breaking cracks;
Embedded cracks under metal surfaces and
Metallurgical change or materials property change.

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4 primary defect categories


Metal Loss Crack-like Geometrical Metallurgical
flaws defects flaws

General (uniform) Fatigue Cracks Dents Toughness reduction


corrosion

Crevice corrosion SCC Gouges Strength reduction

Pitting corrosion Planar fabrication Out-of-roundness Corrosion resistance


flaws reduction

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API 579-1/ASME FFS-1 (2007)

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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Other codes (contd)

Material may be correlated to


equivalent ASME or API specification.

May then apply the acceptance limits


of these fitness for service procedures
unaltered.

User is cautioned to also consider the


effects of fabrication and inspection
requirements on the design basis
(e.g. joint efficiency with respect to
minimum thickness sizing).

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API 579-1/ASME FFS-1 (2007)

API 579-1/ASME FFS-1


Covers present integrity of the component given a current
state of damage and the projected remaining life

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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API 579 PART 2


FITNESS-FOR-SERVICE

ENGINEERING
ASSESSMENT
PROCEDURE

30 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend

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pt 15
API 579-1/ASME FFS-1 (2007)

What is API 579-1/ASME FFS-1?


API 579, first released in 2000,
is a recommended practice for
fitness-for-service that
combines 10 years of effort by
the leading petrochemical
companies.

It gives engineers and


technicians the tools needed to
make run-or-repair decision for
corroded and damaged
equipment.

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What API 579 is not ...

It does not predict how the


degradation will progress.

It evaluates the current


condition or a projected
future condition.

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API 579-1/ASME FFS-1 (2007)

API 579-1/ASME FFS-1


covers situations involving flaws commonly
encountered in the refining and petrochemical
industry in
pressure vessels,
piping and
tankage.

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API 579-1/ASME FFS-1


The procedures are NOT intended to provide a definitive
guideline for every possible situation that may be
encountered.

flexibility is provided to the user in the form of an advanced


assessment level to handle uncommon situations that may
require a more detailed analysis

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API 579-1/ASME FFS-1 (2007)

API 579-1/ASME FFS-1


The assessment procedures are based on allowable stress
methods and plastic collapse loads for non-crack-like flaws,
and FAD-based (Failure assessment diagram ) strategies for crack-
like flaws

Enables user to factor, scale, or adjust the acceptance limits


such that equivalent FFS in-service margins can be attained
for equipment not constructed to these codes.

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Who is involved in fitness-for-


service?
Fitness-for-service, API 579, is multi-discipline:
Materials engineer
Designer (stress analysis)
System engineer
Inspector
Operator

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API 579-1/ASME FFS-1 (2007)

Is fitness-for-service a qualitative
method based on judgment?

A lot of experience has


been compiled in the
document, but it is
primarily a quantitative
method.

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How is the standard structured?


A part for each degradation mechanism.

Each part has three levels of evaluation:


Level 1 Evaluation in the field
Level 2 Evaluation in engineering office
Level 3 Expert evaluation

The standard is self-contained

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API 579-1/ASME FFS-1 (2007)

Three Levels of Evaluation


Provided for each flaw

Level 1 - Evaluation simplified to charts and simple


formulae, generally simplified by conservative
assumptions

Level 2 - Generally requires more detailed evaluation;


more accurate

Level 3 - Allows for flaw assessment by more


sophisticated methods

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Typical Level 1 Limitations


Original design in accordance with a
recognized code or standard

Equipment is not operating in the creep


range

Equipment is not in cyclic service


(fatigue)

Thickness governed by pressure so


equations relate required thickness to
pressure

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API 579-1/ASME FFS-1 (2007)

Level 2 Assessment
Includes components requiring more
complex calculations such as nozzles
and flanges

Includes consideration of supplemental


loads

Includes evaluation of piping systems

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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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pt 21
API 579-1/ASME FFS-1 (2007)

FFS Assessment Steps


Stage Description
1 Flaw and damage mechanism identification.
The first step in a fitness-for-service assessment is to identify the flaw type and cause of damage. The original design and
fabrication practices, the material of construction, and the service history and environmental conditions help to ascertain
the likely cause of the damage.
2 Applicability and limitations of the FFS assessment procedures.
A description of the applicability and limitations of the assessment procedure help the operator to decide whether or not to
proceed with an assessment.
3 Data requirements.
The flaw type or damage mechanism determines the data required. Data requirements may include original equipment design
data, information pertaining to maintenance and operational history, expected future service, and data specific to the FFS
assessment.
4 Assessment techniques and acceptance criteria.
Each section of the code provides assessment techniques and acceptance criteria. If multiple damage mechanisms are pre-sent,
more than one section apply to the evaluation.
5 Remaining life evaluation.
FFS assessment procedures help estimate the remaining life or limiting flaw size to establish an inspection interval.
6 Remediation.
Each section of the code provides remediation methods based on the damage mechanism or flaw type. Remediation techniques
may control future damage associated with flaw growth or material degradation.
7 In-service monitoring.
Each section of the code provides methods for in-service monitoring based on the damage mechanism or flaw type. In-service
monitoring may be used for those cases in which a remaining life and inspection interval cannot adequately be established.
8 Documentation.
Documentation should include a record of all information and decisions made in each of the previous steps to qualify the
component for continued operation.

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REMAINING STRENGTH FACTOR RSF


Remaining strength factor RSF

RSF = LDC / LUC

LDC = limit load (pressure, force, moment) of damaged component


LUC = limit load of undamaged component

Component is acceptable if

RSF > RSFa

RSFa = allowable remaining strength factor = 0.7 to 0.9

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API 579-1/ASME FFS-1 (2007)

Overview of an
FFS Analysis for
Crack-Like Flaws

Using the
Failure Assessment Diagram

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Flaw or damage - Section mechanism Overview


3.0 Brittle fracture Provides assessment procedures for evaluating the resistance to brittle fracture of existing carbon and low alloy steel pressure
vessels, piping, and storage tanks.
Provides criteria to evaluate normal operating, start-up, upset, and shut-down conditions.
4.0 General metal loss Provides assessment procedures to evaluate general corrosion.
Allows either point thickness readings or detailed thickness profiles for thickness data.
Provides a methodology to use the assessment procedures of Section 5.0 when the thickness data indicates that the metal loss can
be treated as localized.
5.0 Local metal loss Provides assessment techniques to evaluate single and networks of local thin areas and groove-like flaws in pressurized
components.
Requires detailed thickness profiles for the assessment.
Can evaluate blisters.
6.0 Pitting corrosion Provides assessment procedures to evaluate widely scattered pitting, localized pitting, pitting which occurs within a region of local
metal loss, and a region of localized metal loss located within a region of widely scattered pitting.
Can evaluate a network of closely spaced blisters.

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).

9.0 Crack-like flaws Provides assessment procedures to evaluate crack-like flaws.


Covers recommendations for evaluating crack growth, including environmental concerns.
10.0 High temperature operation Provides assessment procedures to determine the remaining life of a component operating in the creep regime.
and creep Covers recommendations for evaluating crack growth including environmental concerns.

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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API 579-1/ASME FFS-1 (2007)

Sensitivity Analysis
Consider different assumptions with regard to
loading conditions,
material properties and
flaw sizes

Demonstrate that small changes in input


parameters do not dramatically change the
assessment results

If a strong dependence on an input variable is


found, improve the degree of accuracy used to
establish the value of that variable

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Probabilistic Analysis
Evaluate dependence of
safety margin on uncertainty
of independent variables

Estimate failure probability


using
Monte Carlo simulation,
First order reliability methods
Or other analytical techniques,

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API 579-1/ASME FFS-1 (2007)

Remaining Life Assessment


Remaining life estimates will fall into one of three
general categories

The Remaining Life Can be Calculated With Reasonable


Certainty
Good history & accurate modelling

The Remaining Life Cannot be Established With


Reasonable Certainty
e.g. SCC
Ensure remediation is effective

There is Little or No Remaining Life


Remediation and/or frequent monitoring

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REMAINING LIFE
Remaining life for general metal loss

t am t m in
R life
C rate

Rlife = remaining life, years


tam = averaged measured wall, in
tmin = minimum code required wall, in
Crate = corrosion rate, in/year

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API 579-1/ASME FFS-1 (2007)

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.

Inspection data including all readings utilized in the FFS assessment.

Assumptions and analysis results including:

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
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API

Codes, Standards &


Recommended Practices

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API 579-1/ASME FFS-1 (2007)

API Background
1924 first standard released
(interchangeability of oil field equipment )

Today, over 1000 API standards serve as the


basis for API quality programs covering
production material and lubricants, and
certification programs for storage tanks,
pressure vessels, and piping inspectors.

Based in Washington, D.C. with offices in 27


state capitals

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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.

1911 - court-imposed dissolution of Standard Oil and the


"independents." These companies had no experience working
together, but they agreed to work with the government to
ensure that vital petroleum supplies were rapidly and
efficiently deployed to the armed forces.

The National Petroleum War Service Committee, which


oversaw this effort, was initially formed under the U.S.
Chamber of Commerce and subsequently as a quasi-
governmental body.

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API 579-1/ASME FFS-1 (2007)

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ASME Construction Codes

Boiler & Pressure Vessel Code


B31 Codes for Piping & Pipelines

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API 579-1/ASME FFS-1 (2007)

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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ASME's Boiler and Pressure Vessel Code

More than 2,000 boilers


exploded from 1880 to 1890.

Although numerous boiler


failures in the late 19th century,
there were no legal codes for
boilers in the USA

Code for the Conduct of Trials


of Steam Boilers was ASMEs
more than 1,500 died when a boiler exploded on
first standard, and set in motion the overloaded steamboat Sultana in 1865.
125 years of codes and
standards development.

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API 579-1/ASME FFS-1 (2007)

ASME's Boiler and Pressure Vessel Code

Boiler failure in Brockton, Mass., on March


10, 1905, at the Brockton Shoe Factory
resulted in 58 deaths and 117 injuries, and
completely levelled the factory.

1906 - Massachusetts in 1906 established


a five-man Board of Boiler Rules, whose
charge was to write a boiler law for the
state; this board published its boiler laws
in 1908.

1911 - the ASME Council appointed a


committee to formulate a boiler code,

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ASME's Boiler and Pressure Vessel Code

The first Boiler and Pressure Vessel


Code was published in 1915; as a 114-
page book, measuring 5 x 8 inches.

Today there are 28 books, including a


dozen dedicated to the construction and
in service inspection of nuclear power
plant components, and two Code Case
Books.

The Boiler and Pressure Vessel Code


contains more than 14,000 pages, each
of which measures 81/2 by 11 inches; it
occupies 12 feet of shelf space.

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API 579-1/ASME FFS-1 (2007)

ASME Boiler & Pressure Vessel Code

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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ASME B&PV Volume VIII


Division 1
design, fabrication, inspection, testing, and certification of fired or
unfired pressure vessels operating at either internal or external
pressures exceeding 15 psig. (no max)

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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API 579-1/ASME FFS-1 (2007)

ASME B31 CODES

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ASME B31 CODES

Power Piping - ASME B31.1


Process Piping - ASME B31.3
Liquid Petroleum Transportation Piping - ASME B31.4
Refrigeration piping - ASME B31.5
Gas Transmission and Distribution Piping - ASME B31.8
Building Services Piping - ASME B31.9
Slurry Transportation Piping - ASME B31.11

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API 579-1/ASME FFS-1 (2007)

What is our objective?


To introduce engineers and technicians
to the application of API 579, through
practical exercises.

The participants will apply API 579 to


evaluate the integrity and remaining life
of corroded, cracked, or damaged
tanks, vessels, piping systems and
pipelines.

It is a quantitative technique.
YOU NEED A LAPTOP WITH MS-
EXCEL or equivalent

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Cant I use the existing codes, ASME, to evaluate


the integrity of operating equipment?

The design codes contain acceptance criteria for fabrication flaws,


not for degradation in service.

ASME VIII pressure vessels


ASME B31.3 process piping
ASME B31.4 oil pipeline
ASME B31.8 gas pipeline
API 653 storage tanks

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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API 579-1/ASME FFS-1 (2007)

Is fitness-for-service a code?

With the new release in 2007 API 579


Fitness-for-Service is a STANDARD.

It combines in one place many references


and companies procedures.

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Are there other standards for fitness-for-


service?
API 1104 Ap. A (Alaskan pipeline, 1970s)
ASME B31G for oil and gas pipelines
Canadian Standard Association CSA Z662 Ap. K (earlier CSA Z184, 1986)
DVS Guidelines 2401, Germany, 1996
European Pipeline Research Group EPRG Guidelines (1993 first published)
SINTAP (Structural Integrity Assessment Procedures for European Industry)
PrEN 13445-3, 1998 Fatigue verification of welded joints, European
British Standard Institute BSI PD 6493:1991, replaced by BS7910:1999 (TWI)
Australian Standard AS 2885.2-1995, similar to EPRG, Pipesafe software.
ASME B&PV code Section XI for US nuclear power
British standard R6 for UK nuclear power
NASA Nasgro software (SWRI, Boeing)
SQA/FoU report 96/08, Sweden

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API 579-1/ASME FFS-1 (2007)

API 579 APPENDIX A

THICKNESS - MAWP - STRESS EQUATIONS

69 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend

STRESS DISTRIBUTION

Normal and shear stress at a point.

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API 579-1/ASME FFS-1 (2007)

BASIC EQUATION
CYLINDRICAL SHELL
Hoop (circumferential) stress
PD PR
hoop
2t t

Longitudinal (axial) stress PD PR


axial
4t 2t

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EXERCISE
HOOP STRESS

A pressure vessel has a


diameter of 1300mm and
a wall thickness of 10mm.
It operates at 2000kPa.

What is the hoop stress in


the cylindrical shell? What
is the longitudinal stress?

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API 579-1/ASME FFS-1 (2007)

OVERPRESSURE FAILURE

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API 579 APPENDIX A


THICKNESS - MAWP - STRESS EQUATIONS

Cylindrical shells, thickness for circumferential stress,


pressure only (ASME VIII, UG-27)

PR
t
(SE 0.6P )
m in

tmin = minimum wall of the cylindrical shell, in


P = design pressure, psi
R = inside radius, in
S = allowable stress, psi
E = weld joint efficiency factor

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API 579-1/ASME FFS-1 (2007)

EXERCISE
ASME VIII SHELL

P = 690 kPa
S = 121 MPa SA 515-70 plate @
343oC
E = 0.85 (spot examination)
R = 1219mm

What is the ASME VIII Div.1


required wall thickness of the
cylindrical shell?

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CYLINDRICAL SHELLS

Weld Type 100% RT Spot RT No RT


Double Butt 1.00 0.85 0.70
Or equivalent

Single Butt 0.90 0.80 0.65


(with backing
strip)
Single Butt - - 0.60
(no backing strip)

Double Fillet Lap - - 0.55

Single Fillet Lap - - 0.50


With plug welds

Single Fillet lap - - 0.45


No plug welds

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API 579-1/ASME FFS-1 (2007)

SPHERICAL HEAD

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SPHERICAL HEAD
Spherical or hemispherical head (ASME VIII, UG-27)

PL
t min
( 2 SE 0.2 P )

tmin = minimum wall of head, in


P = design pressure, psi
L = inside radius, in
S = allowable stress, psi
E = weld joint efficiency factor

Hemi. head 100% RT Spot RT No RT


Type 1 1.00 0.85 0.70
Type 2 0.90 0.80 0.65

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API 579-1/ASME FFS-1 (2007)

EXERCISE - ASME VIII


SPHERICAL HEAD

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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API 579-1/ASME FFS-1 (2007)

ELLIPSOIDAL HEAD

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ELLIPSOIDAL HEAD
Elliptical head (ASME VIII, Ap.I)

PD ( K )
t min
2( SE 0.2 P )

tmin = minimum wall of head, in


P = design pressure, psi
RC = inside radius, in
S = allowable stress, psi
E = weld joint efficiency factor
K = (2 + Rell2) / 6
Rell = ratio of major-to-minor axis of
elliptical head = B/A = 2 for 2:1
head (B= 2, A = 1).

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API 579-1/ASME FFS-1 (2007)

ELLIPSOIDAL HEAD
E

Head 100% RT Spot RT No RT


Other than hemi. 1.00 1.00 0.85

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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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pt 42
API 579-1/ASME FFS-1 (2007)

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

tmin = minimum wall of head, in


P = design pressure, psi
L = inside crown radius, in
S = allowable stress, psi
E = weld joint efficiency factor
For t/L 0.002

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pt 43
API 579-1/ASME FFS-1 (2007)

EXERCISE - ASME VIII


TORISPHERICAL HEAD
P = 690 kPa
S = 121 Mpa SA 515-70 plate
@ 343oC
E = 1.0 (seamless)
R = 1219mm
What is the ASME VIII Div.1
required wall thickness of the
torispherical head with L/r =
16.66?

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FLAT HEAD

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API 579-1/ASME FFS-1 (2007)

FLAT HEADS
Flat Heads

CP
t d
SE

t = minimum wall thickness


tr = minimum required thickness of
seamless shell
tS = actual thickness of shell, exclusive
of corrosion allowance
S = maximum allowable stress, psi
E = weld joint efficiency factor

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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?

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pt 45
API 579-1/ASME FFS-1 (2007)

EXERCISE - FLAT HEAD

A heat exchanger has a design


pressure (Maximum Allowable
Working Pressure MAWP) of
2414 kPa at 205oC
It has a 0.915m diameter, and
the allowable stress is 124MPa.
The flat head is seamless.
What is the ASME VIII Div.1
minimum thickness of the flat
head?

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EXERCISE
Pressure vessel

Design pressure = 2068 kPa


Design temperature = 177oC
Inside diameter = 1220 mm
Corrosion allowance = 2.5 mm
Material = SA 516 Grade 70
Weld joint efficiency = 0.85

What is the minimum wall thickness of the cylindrical shell?


Thickness of ellipsoidal head?

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pt 46
API 579-1/ASME FFS-1 (2007)

PIPING SYSTEMS
ASME B31.1 - ASME B31.3

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ASME B31.1 - ASME B31.3


PD
t
2( SEW Py )
P = design pressure, psi
D = outside diameter, in
W = longitudinal weld joint efficiency factor
t =wall thickness, in

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pt 47
API 579-1/ASME FFS-1 (2007)

ASME B31.1 - ASME B31.3


Values of W

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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pt 48
API 579-1/ASME FFS-1 (2007)

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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pt 49
API 579-1/ASME FFS-1 (2007)

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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pt 50
API 579-1/ASME FFS-1 (2007)

ASME B31.4 - OIL PIPELINES


B31.4
PD
t
2S

S = 0.72 E Sy

P = design pressure, psi


D = outside diameter, in
E = longitudinal weld joint efficiency factor
Sy = minimum specified yield stress (MSYS), psi

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EXERCISE
OIL PIPELINE B31.4

P = 4826 kPa at 30oC


D = 500 mm
ERW longitudinal weld E = 1.0
API 5L X42 SY = 42000 psi
(289.6MPa)

What is the minimum wall


thickness required by ASME
B31.4?

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pt 51
API 579-1/ASME FFS-1 (2007)

LONGITUDINAL STRESS IN
PIPELINE

Soil settlement causes a pipeline to bend down 6 over 100 ft.


Pipe is 24 x 0.5 w.t. (D = 24, d = 23) X52 (SMYS = 52 ksi)
8ED 8 (30 106 psi) 24"6"
sBENDING 24ksi
L2 (1200" ) 2
8 8
2 2
6"
S LONGITUDINAL , E (30 106 ) 2ksi
3 L 3 1200"
PD 1200 psi 24"
S LONGITUDINAL , P 14.4ksi
4t 4 x0.5"
S LONGITUDINAL ,TOTAL 24ksi 2ksi 14.4ksi 40.4ksi

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ASME B31.8
GAS PIPELINE

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pt 52
API 579-1/ASME FFS-1 (2007)

ASME B31.8 - GAS PIPELINE


PD
t
2S
S = FET Sy
Values of F
Location class 1, wasteland, desert, mountains, etc. F = 0.72 or 0.8
Location class 2, 10 to 46 buildings within 1 mile, industrial area, F = 0.6
Location class 3, suburbs, F = 0.5
Location class 4, city, F = 0.4

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

P = 4826 kPa at 30oC


D = 500 mm
ERW longitudinal weld E = 1.0
API 5L X42 SY = 42000 psi
(289.6MPa)

What is the minimum wall


thickness required by ASME
B31.8?

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pt 53
API 579-1/ASME FFS-1 (2007)

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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pt 54
API 579-1/ASME FFS-1 (2007)

API 579 PART 3


ASSESSMENT OF EXISTING
EQUIPMENT FOR BRITTLE FRACTURE

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API 579/ASME FFS PART 3


ASSESSMENT OF EXISTING
EQUIPMENT FOR BRITTLE FRACTURE

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pt 55
API 579-1/ASME FFS-1 (2007)

What is Brittle Fracture?


WWII Merchant Ships Etc.
Over 250 ships fractured or cracked. 19 broke completely in two!
Steel not tough enough.

The Great Boston Molasses Tank Disaster


1919. Tank 90 ft diameter and 50 feet high. When the tank split,
a wall of molasses surged down the street.
Steel was below its ductile/brittle transition temperature

The Silver Bridge Collapse


West Virginia December 1967. 46 deaths
Stress-corrosion cracking resulting from long exposure to H 2S
vapour from nearby paper mill digesters.

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pt 56
API 579-1/ASME FFS-1 (2007)

What happened?
2007 in Pembroke, Wales.

Crack in the 30mm pipe allowing release of nitrogen into the


inner space between the SS inner pressure vessel and the CS
outer vessel.

This resulted in pressurisation of the external shell and brittle


facture.

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Assessment of Equipment for


Brittle Fracture

Possible reasons for assessment

Change in operating conditions

HAZOP identifies possibility of lower temperature


condition than considered in design

Equipment rerated using lower design margin

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pt 57
API 579-1/ASME FFS-1 (2007)

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

exemption based on service experience

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Assessment Requirements
Summary of repairs and alterations

Past and future operating conditions

Current design pressure, temperature and current wall


thickness

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pt 58
API 579-1/ASME FFS-1 (2007)

Data
Determine CET loading-temperature envelope

Potential for autorefrigeration due to depressurization

Shock chilling effects

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LEVEL 1 ASSESSMENT

Figure 3.4M Minimum Allowable Metal Temperature


API 579/ASME FFS Page 3-29
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pt 59
API 579-1/ASME FFS-1 (2007)

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.

There is no toughness data on this steel. The vessel was


designed and constructed to ASME B&PV Code Section VIII
Div.1.

Determine the MAT.

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pt 60
API 579-1/ASME FFS-1 (2007)

BRITTLE FRACTURE SHOP


HYDROTEST

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?

If yield stress of the material is 275MPa, how do


you explain the failure?

Apply the following steps to this vessel:


Hydrotest temperature = 10oF
Material belongs to curve B.

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pt 61
API 579-1/ASME FFS-1 (2007)

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)

Minimum Allowable Temperature (MAT):


Lowest metal temperature permitted in design code,
Based on resistance to brittle fracture.

CET > MAT


For MAT use construction code or Curves A to D.
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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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pt 62
API 579-1/ASME FFS-1 (2007)

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

Flowchart figure 3.3

API 620 tanks evaluated as pressure vessels

Levels 1&2 NOT used for atmospheric or LP with


refrigerant

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pt 63
API 579-1/ASME FFS-1 (2007)

STORAGE TANK EXEMPTIONS

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

Part 9 (crack) may be used as a basis for a Level 3


Assessment

Material Toughness

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pt 64
API 579-1/ASME FFS-1 (2007)

Brittle Fracture Wrap Up


Resistance evaluated only of carbon and low alloy
steel units.
Not for Boilers.
Not for ferritic, martensitic or duplex stainless steels

This Part is for screening NOT EVALUATION of


an existing crack.
Use Part 9 for existing cracks.

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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.

Limit impact/shock loading.

Use slow heating and cooling or thermal sleeve to reduce thermal stress.

Avoid low temperature service or hydrotest condition. Reduce residual


stress by PWHT.

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pt 65
API 579-1/ASME FFS-1 (2007)

API 579 PART 4


ASSESSMENT OF GENERAL METAL LOSS

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GENERAL METAL LOSS

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pt 66
API 579-1/ASME FFS-1 (2007)

General Corrosion
Based on local thin area assessment rules

Point thickness readings may be used if metal loss


is confirmed to be general
COV<10%

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Level 1 Analysis

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pt 67
API 579-1/ASME FFS-1 (2007)

C.O.V.
Calculate the average thickness (minimum 15)

Calculate the difference between the actual thickness and the


average for EACH point

Calculate the square

Calculate the COV

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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

We need t and tam (from table 4.2)

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pt 68
API 579-1/ASME FFS-1 (2007)

Inspection Summary (table 4.2)

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Use Point Thickness

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pt 69
API 579-1/ASME FFS-1 (2007)

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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General Corrosion - Level 2


Evaluation methods for shells the same as level 1, but
considers supplemental loads

Evaluation methods provided for components with thickness


interdependencies, such as nozzles, using average thickness
measurements over prescribed lengths

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pt 70
API 579-1/ASME FFS-1 (2007)

Level 1 using CTP


Step 1 Determine tmm

Step 2 - Determine thickness profile data

Step 3 - Determine wall thickness for assessment

Step 4 - Compute remaining thickness ratio

Step 5 - Compute L for averaging length

Step 6 - Establish CTPs


Determine tsam and tcam

Step 7 - Determine acceptability using Table 4.4

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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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pt 71
API 579-1/ASME FFS-1 (2007)

EXERCISE
Results of ultrasonic readings show a corrosion zone along
the longitudinal weld.

The readings are 40mm apart in the circumferential and


longitudinal direction.

Can the vessel be kept in service, or should it be shutdown for


repair?

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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.

A Level 3 Assessment can be performed when the


Level 1 and 2 Assessment procedures do not apply

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pt 72
API 579-1/ASME FFS-1 (2007)

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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pt 73
API 579-1/ASME FFS-1 (2007)

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pt 74
API 579-1/ASME FFS-1 (2007)

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

total number of thickness readings, the number of thickness readings should


be greater than or equal to 15
The equation for the Coefficient of Variation is:

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 Analysis - STEP 1


STEP - 1. Determine the minimum required wall
thickness, and the future corrosion allowance FCA.
Appendix A paragraph A.2
FCA = 0.10

PR 2068 (0.646 0.0025)


t min 13.236mm
SE 0.6 P 120658 0.85 0.6 2068

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pt 75
API 579-1/ASME FFS-1 (2007)

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

From the N measurement points ti, determine the minimum measured


thickness tmm

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LEVEL 1 - STEP 3
Determine thickness for assessment
tc = 19mm 2.5mm
= 17.5mm

Step 4
Remaining thickness ratio

tmm FCA 9.15 2.5


Rt 0.403
tc 16.5

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pt 76
API 579-1/ASME FFS-1 (2007)

LEVEL 1 - STEP 5

Factor Q, if Rt < RSFa. With RSFa = 0.90


If Rt RSFa then Q = 50

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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pt 77
API 579-1/ASME FFS-1 (2007)

LEVEL 1 - STEPS 5 and 6


Step 5 continues - Length for thickness averaging,

L Q Dtc 0.461 1292 16.5 67.36mm


Step 6
Critical thickness profile (CTP) and CTP-FCA

Calculate length s below tmin in the CTP

Readings are spaced 40mm


Readings are below tmin = 13.236mm over s=210mm

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Developing the CTP

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pt 78
API 579-1/ASME FFS-1 (2007)

Determining s and c

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S in CTP

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pt 79
API 579-1/ASME FFS-1 (2007)

LEVEL 1 - STEP 6

Thickness averaging over L


L

t i
9.15 12.2
t am i
10.675
N 2

Take the lowest readings over L = 67.36


mm and average

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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

Condition # 1 (for a shell)


tam - FCA tmin
10.675mm 2.5mm = 8.2mm (NOT 13.236mm) no

Condition # 2 (for a component)


tmm - FCA max{0.5tmin ; 0.10}
9.15mm 2.5mm = 6.65mm 4.575mm yes

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pt 80
API 579-1/ASME FFS-1 (2007)

LEVEL 1 - CONCLUSION
If wall thinning does not comply with level 1
assessment. Proceed with level 2

or derate the pressure to a pressure based on


tC = tam - FCA = 11.783 2.5 = 9.283
and RC = 646 + 2.5 = 648.5mm
120658kPa 0.85 9.7mm
MAWP corroded 1456kPa
648.5mm 0.6 9.7mm

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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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pt 81
API 579-1/ASME FFS-1 (2007)

Level 2 STEP 7
STEP - 7. For pressure vessels and piping, the average
measured thickness should satisfy the following:

For cylindrical and conical shells:


tam FCA RSFa tmin
11.783mm 2.5mm = 9.283 is not 0.90 x 13.236

and for pressure vessel components


tmm FCA max {0.5tmin ; 2.5mm}
9.15mm 2.5mm = 6.65mm 6.618mm yes

Level 2 is not met. Need to derate.

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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)

Cause of corrosion eliminated so FCA = 0 until outage


in 7 months when pipe will be replaced.
Can pipe be left in service for the next 7 months?

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pt 82
API 579-1/ASME FFS-1 (2007)

API 579 PART 5


ASSESSMENT OF LOCAL METAL LOSS

165 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend

Local Thin Areas

Also considers groove-like flaws


Level 1 based on charts & RSF=0.9
Level 2 based on equations
uses Folias factor (see Annex D2.3-p902)
method essentially must be computerized due to large
numbers of repetitive calculations
permits consideration of supplemental loads

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pt 83
API 579-1/ASME FFS-1 (2007)

Remaining Strength Factor

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API 579 PART 5


ASSESSMENT OF LOCAL METAL LOSS

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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pt 84
API 579-1/ASME FFS-1 (2007)

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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pt 85
API 579-1/ASME FFS-1 (2007)

EXERCISE

Ultrasonic inspection shows the


following corrosion profile
C1 C2 C3 C4 C5 C6 C7 C8 C9
M1 29.21 29.21 29.21 29.21 29.21 29.21 29.21 29.21 29.21
M2 29.21 22.10 19.05 17.78 19.30 20.32 21.59 23.88 29.21
M3 29.21 20.57 20.83 21.34 15.75 11.43 16.51 22.86 29.21
M4 29.21 21.59 22.35 20.57 21.34 21.08 22.86 23.11 29.21
M5 29.21 29.21 29.21 29.21 29.21 29.21 29.21 29.21 29.21

Spacing of UT readings is 12mm longitudinal and 25mm


circumferential. The corrosion is away from the weld seam.

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LEVEL 1 - STEP 1(CTP)


Step - 1. Determine the following input:
D = inside diameter = 2438mm
FCA = future corrosion allowance = 2.5mm
Lmsd = distance to structural discontinuity = >1600mm
P =design pressure = 2068kPa
MFH = maximum fill height of tank = if applicable
RSFa =allowable remaining strength factor = 0.90

Determine if the flaw has a gouge or a groove.


A gouge is an elongated mechanical removal of material, much
longer than wide.
A groove is an elongated erosion or corrosion removal of material,
much longer than wide.
gr = radius at base of groove = none

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pt 86
API 579-1/ASME FFS-1 (2007)

STEP 1 determine the CTP


Determine the CTP data

29.21 20.574 19.05 17.78 15.748 11.43 16.51 22.86 29.21


Draw the CTP
35

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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pt 87
API 579-1/ASME FFS-1 (2007)

Level 1 STEP 2
Determine the thickness to be used.
May be determined using Equation (5.4).

tc = trd FCA = 29.21 2.5 = 26.71mm

PR 2068 (1219 2.5)


t min 24.93
SE 0.6 P 120658 0.85 0.6 2068

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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)

29.21 20.574 19.05 17.78 15.748 11.43 16.51 22.86 29.21

t mm = 11.43mm

Calculate the remaining thickness ratio


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pt 88
API 579-1/ASME FFS-1 (2007)

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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Calculate the shell parameter

(1.285) s 1.285 42.2


0.212
Dtc 2438 26.71

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pt 89
API 579-1/ASME FFS-1 (2007)

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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pt 90
API 579-1/ASME FFS-1 (2007)

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:

gr (1 Rt )tc (1 0.334) 26.71 17.79

Else evaluate as a crack (PART 9)

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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)

120658kPa 0.85 26.71mm


MAWP corroded 2214kPa
1221.5mm 0.6 26.71mm

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pt 91
API 579-1/ASME FFS-1 (2007)

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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Level 1 STEP 8 contd


If the flaw is unacceptable, then determine the RSF

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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pt 92
API 579-1/ASME FFS-1 (2007)

Folias
Factor
Mt

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LEVEL 1 - STEP 9.1


The assessment is complete for all component types except cylindrical
shells, conical shells, and elbows.
Step - 9.1
Determine circumferential flaw length parameter
c = 6mm x 3 = 18mm
(1.285)c 1.285 18
c 0.091
35
Dtc 2438 26.71
30

25

20

Series1
15

10

0
1 2 3 4 5
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pt 93
API 579-1/ASME FFS-1 (2007)

Level 1 STEP 9.2


Step 9.2
If the following are satisfied go to STEP 9.3. Else the flaw
is NOT ACCEPTABLE.

c 9 0.094 9 TRUE

D/tc 20 2438/26.71= 91 TRUE

0.7 RSF 1.0


0.7 0.914 1.0 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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pt 94
API 579-1/ASME FFS-1 (2007)

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
.

If the point defined by the


intersection of these values is
on or above the screening
curve, then the circumferential
extent of the flaw is acceptable
per Level 1.

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LEVEL 2 - STEPS 1 TO 7
STEPS 1 thru 7 same as LEVEL 1

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API 579-1/ASME FFS-1 (2007)

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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pt 96
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 8.3


STEP 9 Determine the Remaining Strength Factor for the longitudinal CTP

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LEVEL 2 - STEP 8.4

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API 579-1/ASME FFS-1 (2007)

LEVEL 2 STEP 8.5


STEP 8.5
30
Determine the
28 minimum value of
the Remaining
26 Strength Factors,
RSFi , found in
24
11.43
STEP 9.4 for all
22 subsections (see
Figure 5.8).
20

18 This is the minimum


value of the
16 Remaining Strength
14
Factor for the
current evaluation
12 point.
10
1 2 3 4 5 6 7 8 9

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LEVEL 2 STEP 8 contd


tm x' x'' s' M' table 5.2 A'0 A'/A'0 RSF'

22.86 1.2 7.4 6.2 0.031221 1.0047 165.602 12.58065 1.005107923

20.574 1.5 7.1 5.6 0.028199 1.004 149.576 13.92857 1.004310726

19.05 2.4 6.9 4.5 0.02266 1.0035 120.195 17.33333 1.003715082

17.78 3.6 6.7 3.1 0.01561 1.0026 82.801 25.16129 1.002707902

16.51 4.2 6.4 2.2 0.011078 1.0023 58.762 35.45455 1.002366913

15.748 4.5 6.3 1.8 0.009064 1.002 48.078 43.33333 1.002047341

STEP 8.6 Repeat STEPs 8.3 through 8.5 of this calculation


for the next evaluation point that corresponds to the next
thickness reading location in the ranked thickness profile list.

STEP 8.7 The Remaining Strength Factor to be used in the


assessment, RSF, is the minimum value determined for all
evaluation points.
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API 579-1/ASME FFS-1 (2007)

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.

If a RSF RSFa , then the region of local metal loss is


acceptable for operation at the MAWP determined in STEP 8.
If RSFa < RSF , then the region of local metal loss is
acceptable for operation at reduced MAWP

The MAWP from STEP 8 shall be used in this calculation.

1.002 0.9 TRUE

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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.

If supplemental loads are not present or are not


significant, then circumferential dimension, c , of the flaw
determined from the circumferential CTP should satisfy
the criterion in paragraph 5.4.2.2.i.

If the supplemental loads are significant, then the


circumferential extent of the region of local metal loss shall
be evaluated using the procedures in paragraph 5.4.3.4.

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pt 99
API 579-1/ASME FFS-1 (2007)

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

M2 20 18.5 17.9 18.4 19.6 18.3 18.5 19.9 20

M3 20 19.0 17.4 16.7 16.9 15.4 16.7 17.6 20

M4 20 19.5 18.2 15.6 13.3 8.3 11.9 14.6 20

M5 20 19.3 18.7 16.5 17.5 17.4 18.2 19.0 20

M6 20 20 20 20 20 20 20 20 20

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pt 100
API 579-1/ASME FFS-1 (2007)

API 579 PART 6


ASSESSMENT OF PITTING CORROSION

201 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend

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.

The evaluation of pitting corrosion in API 579 is based on


theoretical and numerical solutions, tests of pitted cylinders
may be conducted in the future.

The API 579 approach is based on ligament efficiency rule of


ASME VIII Div.1, UG-52 (based on 3 and 4 pit groups).
A limit of 80% on pit depth is the same consensus number as
for local thin area.

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API 579-1/ASME FFS-1 (2007)

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.

In a Level 2 approach a sample of pit couples is chosen, and


the pit depth, width, and distance are measured. The pit
region is converted to an equivalent local thin area.

A level-3 approach would be based on finite element analysis,


but this is rarely done for pitting degradation.

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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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API 579-1/ASME FFS-1 (2007)

Level 2
Thickness partitioned into pitted thickness based on average
pit depth, and remaining thickness

Strength of pitted thickness adjusted based on ligament


efficiency

Region of local pitting may be evaluated as LTA with


equivalent thickness

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Level 2
Orientation of pits relative to direction of stress can be
considered

Thickness may be subdivided into a number of thickness


layers

Pitting on both sides can be considered

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API 579-1/ASME FFS-1 (2007)

Level 1 Assessment

4 Different types of pitting

1. widely scattered pitting


2. a local thin area (LTA) located in a
region of widely scattered pitting,
3. localized regions of pitting, and
4. pitting confined within a region of a LTA.

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API 579-1/ASME FFS-1 (2007)

Level 1 Limitations

Not operating in creep range

The original design criteria were in accordance with a


recognized code or standard

The material is considered to have sufficient material


toughness (not brittle)

The component is not in cyclic service (fatigue)

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Level 1 Limitations contd


The following limitations on component types and
applied loads are satisfied:
Level 1 Assessment Type A Components
Level 2 Assessment Type A or B Components

Additional requirements for Level 1 analyses are:


The pitting damage is arrested.
The pitting damage is located on only one surface
(ID or OD) of the component.
The pitting damage is composed of many pits; individual
pits or isolated pairs of pits should be evaluated using the
assessment procedures in Part 5.

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API 579-1/ASME FFS-1 (2007)

Level 2 Limitations

A Level 2 assessment should be


performed if:

An appropriate pit comparison chart


cannot be found
A more detailed assessment of
widespread pitting (e.g. inclusion of the
pit-couple orientation) is required.

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Level 2 Limitations contd


Additional requirements for Level 2
analyses Assessments are:

The pitting damage is characterized by


localized regions of pitting, a LTA located
in a region of widely scattered pitting, or
pitting that is confined within a LTA.

The pitting damage is located on either


one surface or both surfaces of the
component and the pitting damage is not
overlapping.

The pitting damage is composed of many


pits; individual pits or isolated pairs of pits
should be evaluated as LTAs using the
assessment procedures in Part 5.

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API 579-1/ASME FFS-1 (2007)

Level 1 Assessment
Pit charts & max pit depth

The data required for an assessment should include a


photograph (with a reference scale) and/or rubbing of the
surface of the damaged component with an estimate of the
maximum pit depth.

A cross sectional UT thickness scan can also be performed to


determine the pitting profile.

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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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API 579-1/ASME FFS-1 (2007)

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.

Obtain photographs (include reference scale), or rubbings of


this area to record the amount of surface damage.

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API 579-1/ASME FFS-1 (2007)

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).

In Equation (6.3), trd can be replaced by


tnom LOSS

(6.3)

Rwt must be greater than 0.2

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pt 109
API 579-1/ASME FFS-1 (2007)

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.

If the pitting damage is more extensive than that shown in


Figure 6.10, then compute the RSF using the following
equation and proceed to STEP 9.
RSF = Rwt

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API 579-1/ASME FFS-1 (2007)

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.

Interpolation of the RSF is acceptable for intermediate values


of Rwt .

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STEP 9
If RSF RSFa , then the pitting damage is acceptable for
operation at the MAWP determined in STEP 2.

If RSF < RSFa , then the region of pitting damage is


acceptable for operation at MAWPr, where MAWPr is
computed using the equations in then the component can be
rerated using the equations in Part 2, paragraph 2.4.2.2.

The MAWP from STEP 2 shall be used in this rerating


calculation,.

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API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

LEVEL 2 STEP 2

Determine the wall thickness to be


used in the assessment

= 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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pt 113
API 579-1/ASME FFS-1 (2007)

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.

In the following equation, the subscript k represents a calculation


for pit-couple k.

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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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API 579-1/ASME FFS-1 (2007)

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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pt 115
API 579-1/ASME FFS-1 (2007)

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.

Determine the average value of the Remaining Strength


Factors, RSFk , found in STEP 7 and designate this value as
RSFpit for the region of pitting.

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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

2) Localized Pitting If the pitting damage is localized,


then the damaged area is evaluated as an equivalent
region of localized metal loss

3) Region Of Local Metal Loss Located In An Area Of


Widespread Pitting If a region of local metal loss
(LTA) is located in an area of widespread pitting, then
a combined Remaining Strength Factor can be
determined

4) Pitting Confined Within A Region Of Localized Metal


Loss If the pitting damage is confined within a
region of localized metal loss (see Figure 6.14), then
the results can be evaluated using the methodology in
subparagraph 3) above.

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STEP 10
Check the recommended limitations on the
individual pit dimensions:

1) Pit Diameter If the following equation is not satisfied


for an individual pit, then the pit should be evaluated as a
LTA. The size of the LTA is the pit diameter and the
remaining thickness ratio is defined below.
Q from Part 4 table 4.4

2. Pit Depth The following limit on the remaining


thickness ratio is recommended to prevent a local failure
characterized by pinhole type leakage

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pt 117
API 579-1/ASME FFS-1 (2007)

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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Level 1 Pitting Exercise


Pressure Vessel with
pitting on the inside
surface
Di = 250mm
FCA = 3mm
250mm
Trd = 13mm (LOSS=0)
Max pit depth = 6.4mm

Can the vessel be


returned to service if the
pitted area is recoated?
350mm

Use RSFa=0.9

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pt 118
API 579-1/ASME FFS-1 (2007)

EXERCISE - PITTING
P = 700 psi @ 70oF
API 5L X40 20 w.t. 0.25, ERW
Two pit couples

Couple 1-2 3-4


depth odd pit 0.08 0.06
depth even pit 0.10 0.08
width odd pit 0.5 1.0
width even pit 0.5 0.8
pitch in couple 2 2

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API 579 PART 7

BLISTERS, HIC & SOHIC

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API 579-1/ASME FFS-1 (2007)

SCOPE

Hydrogen blisters, HIC and SOHIC

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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.

Low temperature, wet H2S service


or HF service.

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pt 120
API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

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

Permits evaluation of blisters adjacent to weld seams

Permits evaluation of laminations in hydrogen charging


service

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API 579-1/ASME FFS-1 (2007)

MULTIPLE BLISTERS

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LEVEL 1
Step - 1. Assemble the following
information

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API 579-1/ASME FFS-1 (2007)

LEVEL 1 - BLISTER
Step - 2. Blisters are acceptable, without repair, if

One of these 2 conditions is met


The blister diameter is 50mm or less, or
The blister diameter is 0.6(Dtnom)0.5 or less (D is the shell ID).
The blister projection above the surface BP is less than
10% of the blister diameter.
The min. measured thickness tmm is 1/2 the plate
thickness or more.
There are no cracks in and around the bulge.
Distance to welds is more than max{25mm ; twice wall}
Distance to structural discontinuity is 1.8(Dtnom)0.5 or more

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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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API 579-1/ASME FFS-1 (2007)

Blister Level 2 contd


STEP 4
If the blister has periphery cracks toward either
the internal or external surface, then proceed to
STEP 5; otherwise, proceed to STEP 6.

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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Blister Level 2 contd


STEP 6
If the blister does not have a crown crack, then proceed to
STEP 7. If the blister has a crown crack, then proceed to
STEP 9.

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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pt 125
API 579-1/ASME FFS-1 (2007)

Blister Level 2 contd


STEP 8
Blister vented go to STEP 10
Blister not vented go to STEP 11

STEP 9
Evaluate as LTA

STEP 10
If go to STEP 12
Else go to STEP 11

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Blister Level 2 contd


STEP 11
An in-service monitoring system should be developed to
monitor blister growth while the component is in service,
go to STEP 12.

STEP 12
The Level 2 Assessment is complete, the component may
be returned to service.

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pt 126
API 579-1/ASME FFS-1 (2007)

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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pt 127
API 579-1/ASME FFS-1 (2007)

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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Hydrogen Induced Cracking

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pt 128
API 579-1/ASME FFS-1 (2007)

Data Required for Assessment


HIC Spacing to Nearest HIC or Blister, H L and Hs
HIC Spacing to Weld Joints, LW
HIC Spacing to Major Structural Discontinuities, Lmsd
HIC Through-Thickness Extent of Damage, H w
Minimum Remaining Wall Thickness of Undamaged Metal, Internal
Side, tmm ID
Minimum Remaining Wall Thickness of Undamaged Metal, External
Side, tmm OD
Minimum Remaining Wall Thickness of Undamaged Metal, Total,
tmm
HIC Damage Dimensions, s and c

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HIC Damage

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API 579-1/ASME FFS-1 (2007)

HIC Level 1 Assessment

STEP 1 Gather the data


STEP 2 Determine the wall thickness
to be used in the assessment

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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:

The through-thickness extent of the damage satisfies

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API 579-1/ASME FFS-1 (2007)

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

Further HIC damage has been prevented by a barrier coating


or no further hydrogen charging of the metal will occur

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Software
VCESage

CodeCalc

ENG-Fit

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pt 131
API 579-1/ASME FFS-1 (2007)

VCESage Brittle Fracture

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VCESage - Pitting

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pt 132
API 579-1/ASME FFS-1 (2007)

VCESage - LTA

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ENG-Fit TWI

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pt 133
API 579-1/ASME FFS-1 (2007)

API 579 PART 8

ASSESSMENT OF WELD MISALIGNMENT


AND SHELL DISTORTIONS

267 API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend

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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pt 134
API 579-1/ASME FFS-1 (2007)

Weld Misalignment and Shell


Distortions
Permits consideration of general shell distortion,
out-of-roundness, bulges and dents

Level 1 based on comparison to limits of new construction


code
Level 2 based on stress analysis; equations are provided
Fatigue analysis may be required

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LEVEL 1
Fabrication tolerance of applicable construction code.

ASME VIII Pressure Vessel


Shell: 1% out-of-roundness internal pressure
Heads: 1.25% of outside shape, 0.625% inside shape.
Weld offset misalignment, longitudinal weld:
t < 1/2 e = t/4
t = 1/2 to 3/4 e = 3/16
Weld offset misalignment, circ. Weld
t < 3/4 e = t/4
t = 3/4 to 1-1/2 e = 3/16

ASME B31.3 Process Piping


Out-of-Roundness
8% internal pressure

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pt 135
API 579-1/ASME FFS-1 (2007)

LEVEL 1

API 620 and 650 Tank


Out-of-plumb 1/200 total height
Out-of-Round 1%
Out-of-Round 1 ft from bottom
D < 40 t radius 1/2 tolerance
D = 40 to 150 ft radius 3/4 tolerance
Weld offset misalignment - Butt joint
t < 1/4 e = 1/16
t > 1/4 e = min {t/4 ; 1/8}

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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

1. If the component under evaluation is a cylinder with


out-of-roundness, the out-of-roundness must be
constant along the axis of the cylinder.

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pt 136
API 579-1/ASME FFS-1 (2007)

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

Global out of roundness

Local Peaking - Cylinder and Sphere

Ovalisation of a pipe bend


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pt 137
API 579-1/ASME FFS-1 (2007)

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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pt 138
API 579-1/ASME FFS-1 (2007)

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

12(1 0.3 )31517.75 0.05


2


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

Ratio of induced bending stress to applied membrane stress


for the longitudinal joint of a cylinder with angular
misalignment is
6 6 0.31"
Cf 0.83 3.43
clja
Rb
t FCA 0.5"0.05"

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API 579-1/ASME FFS-1 (2007)

PEAKING LEVEL 2 -
STEP 4

Step 5 Remaining strength factor


HS 3 16800psi
RSF
f a
0.90
(1 R ) 12579psi(1 3.43)
m b

Step 6
Compare RSF to allowable RSFa = 0.90
In this case, OK.

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PEAKING WITH FATIGUE


Can the pipe cycle 200 times 0 to 315 psi?

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

Srange = max{55725-0 ; 0-0; 0-55725} = 55725 psi

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API 579-1/ASME FFS-1 (2007)

PEAKING WITH FATIGUE


Step 3
Determine the alternating stress

Srange = 55725 psi


3Sm < Srange < 3mSm

3 x 16800 < 55725 < 3 x 3 x 16800

Salt = (Srange/2) Ke = (68304/2) 1.72 = 58741 psi

Salt = 5.8 104 psi


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PEAKING WITH FATIGUE


Step 4
Enter the fatigue curve and read number of
cycles

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pt 141
API 579-1/ASME FFS-1 (2007)

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

Dmax - Dmin = 120.5 - 119.4 = 1.1 1%D = 1.2 OK


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API 579-1/ASME FFS-1 (2007)

OVALITY - LEVEL 2 -
STEP 1
Step 1: collect data

E = 26.1 106 psi


FCA = 0.125
Hf = 3.0
P = 500 psi
R = 60
Sa = 17500 psi
t = 1.875
= 0.3
= 0o (longitudinal weld seam location at 3 oclock)
Cs = 0.1 deformed shape significantly deviates from perfect oval (0.5 is ~ perfect oval)
D = 2R = 120
Dmax = 120.5
Dmio = 119.4

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OVALITY - LEVEL 2 - STEPS 2


AND 3
Step 2

membrane stress P R FCA


0.6
E t FCA
m

500psi 60 0.125
0.6 17479psi
1.0 1.875 0.125

Step 3 induced bending / applied membrane ratio

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

1.5(120.5 119.4) cos 0 o

0.593
500psi(1 0.3 ) 122 2

(1.875 0.125)1 0.1


26.1 10 psi 1.875 0.125 6

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pt 143
API 579-1/ASME FFS-1 (2007)

EXERCISE - OVALITY STEPS 4


AND 5

Step 4

H S 3 17500psi
RSF f a
1.0
(1 R 17479psi(1 0.593)
or

m b
)

use RSF = 1.0

Step 5

RSF = 1.0 > RSFa = 0.9

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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pt 144
API 579-1/ASME FFS-1 (2007)

API 579 PART 9


ASSESSMENT OF CRACK-LIKE FLAWS

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CRACK FABRICATION (MILL - SHOP)


CONSTRUCTION (FIELD)

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pt 145
API 579-1/ASME FFS-1 (2007)

CRACK IN-SERVICE
CORROSION (ENVIRONMENTAL EFFECT)

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CRACK IN-SERVICE
3RD PARTY DAMAGE

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pt 146
API 579-1/ASME FFS-1 (2007)

INTRODUCTION TO
FRACTURE MECHANICS
Fracture mechanics: Sensitivity of structures
(equipment, airplane fuselage, pressure vessels,
pipelines, etc.) to cracks.

Early research in fracture mechanics dates to


1920s and 1930s (A. Grifith, 1920, H.M.
Westergaard, 1939).

The origins of modern fracture mechanics are in


aeronautics: F. Erdogan, George Irwin, Hiroshi
Tada, Paul Paris.
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SIMPLE RULE - COMPLEX


PHENOMENON
A crack in a component is stable under operating
load (pressure, temperature, etc.) if the stress
intensity at the crack tip (K) is smaller than a limit
KC (fracture toughness) that depends on the
material, the temperature and the strain rate.

K < KC

Why is it important? What is the stress intensity?


What is the fracture toughness?

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pt 147
API 579-1/ASME FFS-1 (2007)

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?

Fracture mechanics will not tell us if the crack will continue to


grow. This depends on corrosion or fatigue in service.

Fracture mechanics will tell us if the crack will rupture or not, if


the component will leak or break.

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THREE FAILURE MODES

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pt 148
API 579-1/ASME FFS-1 (2007)

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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FRACTURE TOUGHNESS KIC


See Appendix F.
Fracture toughness can also be estimated (very roughly) from CVN

5(CVN )
K IC
S y
0.25
S y

Sy = yield stress, ksi


CVN = Charpy vee-notch impact toughness, ft-lb

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pt 149
API 579-1/ASME FFS-1 (2007)

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EXERCISE

Estimate the fracture toughness of a


steel that has a yield stress of 60 ksi
and a CVN of 50 ft-lb at the minimum
operating temperature.

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pt 150
API 579-1/ASME FFS-1 (2007)

LEVEL 1
Step - 1. Determine MAWP (design pressure, MAOP), and temperature, and operating
loads.
MAWP = 3450kPa
T = 21oC
Material is PWHT

Step - 2. Determine length and depth of crack.


Base metal crack, longitudinal is shell (cylinder)
Crack depth = 20% t = t / 5
crack length = 6

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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pt 151
API 579-1/ASME FFS-1 (2007)

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

Is crack acceptable by level 1?

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pt 152
API 579-1/ASME FFS-1 (2007)

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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pt 153
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 2

Step - 2. Determine the nominal


stress distribution at the location of the
flaw. Classify stresses as
Primary (membrane and bending)
Secondary
Residual

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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)

residual = SY* = 62 ksi @ ID


up to 20% SY* = 12.4 ksi @ OD

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pt 154
API 579-1/ASME FFS-1 (2007)

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

KIC = 100 ksi(in)0.5


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LEVEL 2 - STEP 4

Step - 4. Characterize the crack

360o all around 20% through wall from


OD

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pt 155
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 5
Step - 5. Apply the partial safety factors

Primary Stress Correction

Pm = Pm PSFS
Pb = Pb PSFS

Material Toughness

KIC = KIC / PSFk

Flaw Size

surface flaw a = a PSFa


embedded flaw 2a = 2a PSFa
through-wall flaw 2c = 2c PSFa

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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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pt 156
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 6

Step - 6. Compute the reference


primary stress refp from Appendix D.
P 9( ZP )
2 2
P
re f
b b m

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

ref ZPm 1.3 1.40 14.4ksi 26.2ksi

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pt 157
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 7
Step - 7. Calculate the ratio Lrp

P
26.2
ref 0.50
p
Lr
SY 52

refp = reference primary stress (step-6) = 26.2 ksi


Sy = material yield stress (step-3) = 52 ksi

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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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pt 158
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 9
Step - 9. Compute the reference stress for secondary and residual stresses
refSR (Appendix D).

Secondary stress distribution through-wall


4 ksi @ OD
assume ~ 4 ksi at ID
i.e. assume membrane (constant) 4 ksi through-wall

Residual stress distribution through-wall


62 ksi @ ID
0.2 x 62 ksi = 12 ksi @ OD

Secondary + residual stress distribution through wall


66 ksi @ ID
16 ksi @ OD
= 41 ksi membrane 25 ksi bending
PSFS = 1.4 57.4 ksi membrane 35 ksi bending
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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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pt 159
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 10
Step - 10. Compute the secondary and residual stress reduction
factor

If refRS > SY

26.2
P

Srf min (1.4 ref ;1 min (1.4 ;1


S flow 62
min{ 0.98;1} 0.98

If refRS < SY

Srf = 1.0

refp = reference stress associated with primary stress


f = flow stress = SY + 10 ksi
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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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pt 160
API 579-1/ASME FFS-1 (2007)

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

= 1.0 for plane stress, 3.0 for plane strain

Then enter curve with Lrp and read / o, obtain .


LrP = 0.50 (step 7) and LrS = 3.5 (step 9)
/ o = 1.22
= 1.22 x 1.66 = 2
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pt 161
API 579-1/ASME FFS-1 (2007)

LEVEL 2 - STEP 12

Step - 12. Determine the toughness ratio

K I 18.6 2 60
P SR
KI
Kr 1.98
K IC 70

Step -13. Enter the failure assessment


diagram, and decide if the flaw is
acceptable.

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FAILURE ASSESSMENT
DIAGRAM

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pt 162
API 579-1/ASME FFS-1 (2007)

LIQUID LEAK RATE


THROUGH CRACK
The crack opening area is

COA = 2C2 / E

= applied membrane tensile stress


C = half length of through-wall crack

For a longitudinal crack in a cylinder


= 1 + 0.1 +0.16 2
= 1.818C/(Rit)0.5

For a circumferential crack in a cylinder


= (1 + 0.117 2)0.5
= 1.818C/(Rit)0.5

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CRACK OPENING AREA -


EXAMPLE
P = 747 psi
Ri = 27.0
t = 0.63

Membrane hoop stress


hoop = PD / (2t) = 747 x 54.6 / (2 x 0.63) = 32,400 psi

Membrane longitudinal stress


longitudinal = 32,400 / 2 = 16,200 psi

Flaw length
2C = 6 x depth = 6 x wall = 6 x 0.63 = 3.78

C = 1.89

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pt 163
API 579-1/ASME FFS-1 (2007)

CRACK OPENING AREA -


EXAMPLE
= 1.818 x 1.89 / (27 x 0.63)0.5 = 0.8332

= 1.194 longitudinal crack

= 1.037 circumferential crack

E = Youngs modulus in plane stress 28x106 psi

Crack opening area for a longitudinal crack

COA = 2 x 32,400 x 1.892 x 1.194 / 28 106

COA = 0.031 in2

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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

q = 0.61 x 2.15 10-4 (2 x 32.2 x 144 x 747 / 62.4)0.5

q = 0.044 ft3/sec = 2.64 ft3/min = 2.64/0.134 gpm


~ 20 gpm
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pt 164
API 579-1/ASME FFS-1 (2007)

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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API 579 PART 10


ASSESSMENT OF COMPONENTS

OPERATING IN THE CREEP RANGE

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pt 165
API 579-1/ASME FFS-1 (2007)

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.

The component does not contain:


1) An LTA or groove-like flaw,
2) Pitting damage,
3) Blister, HIC, or SOHIC damage,
4) Weld misalignment, out-of-roundness, or bulge that exceed the
original design code tolerances,
5) A dent or dent-gouge combination,
6) A crack-like flaw, or
7) Microstructural abnormality such as graphitization or hydrogen
attack.

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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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pt 166
API 579-1/ASME FFS-1 (2007)

Level 2
Limitations:

The Level 2 assessment procedures in this Part apply only


if all of the following conditions are satisfied:

a) The original design criteria were in accordance with Part


2, paragraph 2.2.2.
b) A history of the operating conditions and documentation of
future operating conditions for the component.
c) The component has been subject to less than or equal to
50 cycles of operation including startup and shutdown
conditions, or less than that specified in the original design.
d) The component does not contain any of the flaws listed in
paragraph 10.2.2.1.d).

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Level 3
Use Level 3 assessment if the following apply:

Advanced stress analysis techniques are required due to


complicated geometry and/or loading conditions
Cyclic operation
Contains a flaw listed in paragraph 10.2.2.1.d)

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API 579-1/ASME FFS-1 (2007)

Required Data for A FFS Assessment

Level 1 Level 2 Level 3

Original design data



Maintenance & Operational history

Nominal stresses

Detailed stress analysis

Material properties

Damage characterisation

NDE methods used

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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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API 579-1/ASME FFS-1 (2007)

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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Boiler tube thickness factor


e=0.0 for tubes strength welded to headers and drums
e=0.04 over a length equal to the length of the seat plus 25
mm ( 1in.) for tubes expanded into tube seats, except e=0.0
for tubes expanded into tube seats provided the thickness of
the tube ends over a length of the seat plus 25 mm (1 in.) is
not less than the following:
2.41 mm (0.095 in) for tubes 32 mm (1.25 in) OD and smaller,
2.67 mm (0.105 in) for tubes above 32 mm (1.25 in) and up to 51 mm
(2 in.) inclusive,
3.05 mm (0.120 in) for tubes above 51 mm (2 in) and up to 76 mm (3
in.) inclusive,
3.43 mm (0.135 in) for tubes above 76 mm (3 in) and up to 102 mm (4
in.) inclusive,
3.81 mm (0.150 in) for tubes above 102 mm (4 in) and up to 127 mm (5
in.) inclusive.

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API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

Case History 1
Cracked ring-joint flange.

A hydrogen processing vessel had cracks in the ring-groove radius region of a


ring-joint flange. The operator conducted an FFS assessment based on an
FEA.
The analysis and fracture-mechanics concepts indicated that the driving force
for crack propagation was high for a very localized region near the ring groove
radius.
Crack propagation decreased significantly, however, for deeper cracks.
The assessment also showed that the highest stresses occurred during the
bolt-up operation. The chemistry, grain size, microstructure, and hardness of
the material indicated that the material had good resistance to hydrogen-
assisted crack growth during downtimes and to crack advances during service.
Based on the results of the FFS, the engineering and inspection team
recommended that starting up the unit without repair of flange cracks.
The plant realized a substantial cost savings from avoidance of repairs and
extension of the shutdown duration.

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Case History 2
Severe out-of-roundness of a new pressure vessel.

During field erection in a petrochemical plant, one company


accidentally dropped a new pressure vessel. The vessels shell
distorted in excess of ASME code limits.
The operator used an FFS assessment to evaluate the integrity
of the distorted shell under internal pressure loading. Engineers
constructed a finite-element model of the distorted geometry
based on field measurements. The assessment included an
evaluation of the collapse strength under internal pressure
loading as well as a fatigue assessment.
The results of the FFS assessment indicated that the vessel
shell was acceptable for future operation at the original design
conditions. The use of FFS technology eliminated the need for
costly repairs to the new vessel as well as significant costs
associated with unplanned operational interruption.

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API 579-1/ASME FFS-1 (2007)

Case history 3
Fire-damaged vessel.

A major fire in a refinery resulted in excessive distortion of


the shell of a vacuum tower. Using field measurements of
the distorted shell profile, the refinery performed an FFS
assessment to evaluate the structural integrity of the
damaged shell.
The assessment indicated that the integrity of the vessel
had not been compromised.
This evaluation eliminated the need for costly repairs and
avoided an extension of the unplanned shutdown,
resulting in savings of more than $500,000.

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Case History 4
Creep life assessment of a refinery pressure vessel.

One refinery conducted an FFS assessment to evaluate a fluid-


catalytic cracking reactor vessel that had operated in the creep
range for almost 45 years. An initial damage assessment based
on elastic stress analysis indicated that the vessel was
approaching its predicted failure life. Thus, there was little
potential for increasing the operating temperatures.
In this situation, engineers performed an FFS assessment that
included material testing of vessel samples and using nonlinear
FEA to re-evaluate the vessel.
The assessment indicated that operation at increased
temperatures was feasible for a projected time of 20 years. The
owner saved about $4 million associated with process
improvements and the avoidance of vessel replacement.

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API 579-1/ASME FFS-1 (2007)

API 579 PART 11


ASSESSMENT OF FIRE DAMAGE

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FIRE DAMAGE

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API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

APPLICABILITY
Vessel, piping and tank condition following a fire: should it be used-as-is?
repaired? replaced?

Degradation from fire is


Visible structural
Invisible mechanical, corrosion resistance

Pressure vessels, tanks and piping systems.

For floating tank roofs and tank bottom, also refer to API 653.

Does not address non-pressure retaining structures (ladders, platforms, etc.).

Does not address electrical distribution and control system.

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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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API 579-1/ASME FFS-1 (2007)

HEAT EXPOSURE ZONE

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HEAT EXPOSURE ZONE

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API 579-1/ASME FFS-1 (2007)

HEAT EXPOSURE ZONE

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HEAT EXPOSURE ZONE

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API 579-1/ASME FFS-1 (2007)

ZONE III

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ZONE IV

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API 579-1/ASME FFS-1 (2007)

ZONE V

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ZONE VI

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API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

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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STEEL COLOR SPECTRUM

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API 579-1/ASME FFS-1 (2007)

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)

313 330 150

243 255 120

190 200 90

143 150 70

124 130 60
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API 579-1/ASME FFS-1 (2007)

LEVEL II
Determine the allowable stress

Safd = Cism Suht (SaT / SaA)


But noless than SaT

Safd = allowable stress for fire damage


Cism = 0.25 margin
Suht = ultimate strength based on hardness test
SaT = code allowable stress at design temp.
SaA = code allowable stress at ambient temperature

Step 3. Calculate MAWP using Safd.

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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API 579-1/ASME FFS-1 (2007)

EXERCISE

Fire damage:

Melted aluminum conduit next to vessel.


Vessel not sagged.
Iron oxide scale spalled off fire side of vessel.
Paint discoloration opposite side of fire source.
No damage by visual internal.
Wall thinning from service is 0.03.
Oil inside vessel in good condition.
Hardness measured 132 HB hot side, 152 HB cool side.

Based on the melted Al conduit what was the local temperature?


What heat exposure would you assign?
Would the vessel be operable by a level 1 evaluation?
Would the vessel be operable by a level 2 evaluation?

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PART 12

ASSESSMENT OF DENTS,
GOUGES, AND DENT-
GOUGE COMBINATIONS

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API 579-1/ASME FFS-1 (2007)

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.

b) Gouge An elongated local


removal and/or relocation of material
from the surface of a component
caused by mechanical means that
results in a reduction in wall
thickness;

c) Dent-Gouge Combination A dent


with a gouge present in the deformed
region.

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Limitations
Must have sufficient toughness
Consider the damage may result in cold work

Must be cylindrical shell

Maximum load = internal pressure

Damage is to inward
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API 579-1/ASME FFS-1 (2007)

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.

Level 2 Assessment limited to dent-gouge combinations in carbon


steel cylindrical shells located away from structural discontinuities. A
remaining strength factor approach is utilized to determine an
acceptable MAWP based on the dent depth and gouge depth. In
addition, a fatigue assessment to evaluate the effects of cyclic
pressure loading is provided.

Level 3 Assessment rules are intended to evaluate dent-gouge


combinations in complex geometries subject to general loading
conditions. A Level 3 Assessment is also required for materials other
than carbon steel. Numerical stress analysis techniques are utilized
in a Level 3 assessment.

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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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API 579-1/ASME FFS-1 (2007)

Level 1 contd
Determine thickness and gouge depth to be used in the
assessment

Ensure the following requirements are satisfied:

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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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API 579-1/ASME FFS-1 (2007)

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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API 579-1/ASME FFS-1 (2007)

PART 13

Laminations

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Definition

Laminations are a plane of non-fusion in the interior


of a steel plate that results from the steel
manufacturing process.

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API 579-1/ASME FFS-1 (2007)

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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 the lamination has any evidence of an associated surface bulge, then it


shall be evaluated as a blister using the Level 1 blister assessment
procedures of Part 7.

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.

If the lamination has a through-wall component (i.e. not parallel to the


surface), then the through-wall component is evaluated as a equivalent
crack-like flaw using the Level 1 assessment procedures of Part 9

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API 579-1/ASME FFS-1 (2007)

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:

API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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API 579-1/ASME FFS-1 (2007)

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.

API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Lamination Level 2
Essentially the same as Level 1

EXCEPT STEP 6-5

If the lamination is in hydrogen


charging service, then the
lamination shall be evaluated as an
equivalent local thin area using the
methods of Part 5.

The remaining sound metal


thickness to use in the LTA
analysis is the value of
max [( tc Lh tmm), tmm]
and the longitudinal and
circumferential extend of the LTA
are s and c , respectively.

API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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What have we learned?


The FFS techniques described herein are
essentially based on STRENGTH.

The techniques are computational.

IT IS EASY TO MAKE MISTAKES.

For iterative computations use proven


methodology. E.g. MS-Excel.

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The Test

This is an open book test.

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And now to work

GOOD LUCK

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