asme api 579 si handouts
DESCRIPTION
API 579 Fitness for Service FFS by Ron Frend. Pdf of slides used in the presentation training course. Use to evaluate severity of damage mechanisms to the pressure envelope of static equipment in the oil and gas industry.TRANSCRIPT
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API 579-1/ASME FFS-1 (2007)
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pt 1
Document version 2011/01/v1.4 Last update - 21 Sept 2011
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend 1
API 579-1/ASME FFS-1
Fitness for Service
of Piping, Vessels and Tanks
Document version 2011/01/v1.4 Last update - 21 Sept 2011
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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.
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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PROGRAMME OBJECTIVES Understand FFS for static, mechanical equipment
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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
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
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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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What is FFS? ASME and API codes for pressurized equipment do not
address in-service equipment degradation nor deficiencies in original fabrication.
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).
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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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 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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Technical Integrity Plan: Risk Reliability Management
Asset Register
Action: Preventive Maintenance
Corrective Maintenance
Inspection
Operation
Check: Deviation Control
Technical Authorities
Risk Management
Analyse: Root Cause Analysis
Fitness for Purpose
Improve: Change Management
Modification Projects
Specifications
Procedures
Standards
Specifications
Procedures
Standards
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
Overview of API 579-1/ASME FFS-1
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
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
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 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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FFS Requirements
Require an interdisciplinary approach with operations personnel consisting of an understanding of
Damage mechanisms and material behaviour.
Past and future operating conditions.
Non-destructive examination techniques (flaw location and sizing).
Material properties (environmental effects).
Stress analysis (finite element analysis; FEA) and
Data analysis (engineering reliability models).
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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4 primary defect categories
Metal Loss Crack-like flaws
Geometrical defects
Metallurgical flaws
General (uniform) corrosion
Fatigue Cracks Dents Toughness reduction
Crevice corrosion SCC Gouges Strength reduction
Pitting corrosion Planar fabrication flaws
Out-of-roundness Corrosion resistance reduction
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Other codes
When evaluating other codes and standards
the following should be considered:
Material specifications
Upper and/or lower temperature limits for specific materials
Material strength properties & design allowable stress basis
Material fracture toughness requirements
Design rules for shell sections
Design rules for shell discontinuities such as nozzles
Design requirements for cyclic loads.
Design requirements for operation in the creep range
Weld joint efficiency or quality factors
Fabrication details and quality of workmanship
Inspection requirements, particularly for welded joints
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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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
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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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API 579 PART 2
FITNESS-FOR-SERVICE
ENGINEERING
ASSESSMENT
PROCEDURE
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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)
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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
covers situations involving flaws commonly
encountered in the refining and petrochemical
industry in
pressure vessels,
piping and
tankage.
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
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)
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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
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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Level 2 Assessment
Includes components requiring more
complex calculations such as nozzles
and flanges
Includes consideration of supplemental
loads
Includes evaluation of piping systems
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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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 distortions
Provides assessment procedures to evaluate stresses resulting from geometric discontinuities in shell type structures including weld 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 and creep
Provides assessment procedures to determine the remaining life of a component operating in the creep regime. 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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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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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
Rlife = remaining life, years
tam = averaged measured wall, in
tmin = minimum code required wall, in
Crate = corrosion rate, in/year
rate
minam
life
C
ttR
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Documentation
The equipment design data, and maintenance and past operational history to the extent available should be documented for all equipment subject to a FFS assessment.
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
Fracture
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API
Codes, Standards &
Recommended Practices
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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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ASME Construction Codes
Boiler & Pressure Vessel Code
B31 Codes for Piping & Pipelines
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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 first standard, and set in motion 125 years of codes and standards development.
more than 1,500 died when a boiler exploded on
the overloaded steamboat Sultana in 1865.
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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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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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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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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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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 APPENDIX A
THICKNESS - MAWP - STRESS EQUATIONS
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STRESS DISTRIBUTION
Normal and shear stress at a point.
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BASIC EQUATION
CYLINDRICAL SHELL
Hoop (circumferential) stress
Longitudinal (axial) stress
t
PR
t2
PDhoop
t2
PR
t4
PDaxial
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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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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)
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
)P6.0SE(
PRt
min
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EXERCISE ASME VIII SHELL
P = 690 kPa
S = 121 MPa SA 515-70 plate @ 343oC
E = 0.85 (spot examination)
R = 1219mm
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 ButtOr equivalent
1.00 0.85 0.70
Single Butt(with backing
strip)
0.90 0.80 0.65
Single Butt(no backing strip)
- - 0.60
Double Fillet Lap - - 0.55
Single Fillet LapWith plug welds
- - 0.50
Single Fillet lapNo plug welds
- - 0.45
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SPHERICAL HEAD
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SPHERICAL HEAD
Spherical or hemispherical head (ASME VIII, UG-27)
tmin = minimum wall of head, in
P = design pressure, psi
L = inside radius, in
S = allowable stress, psi
E = weld joint efficiency factor
E
Hemi. head 100% RT Spot RT No RT
Type 1 1.00 0.85 0.70
Type 2 0.90 0.80 0.65
)2.02(min
PSE
PLt
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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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ELLIPSOIDAL HEAD
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ELLIPSOIDAL HEAD
Elliptical head (ASME VIII, Ap.I)
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).
)2.0(2
)(min
PSE
KPDt
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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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TORISPHERICAL HEAD
(FLANGED AND DISHED HEAD)
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TORISPHERICAL HEAD
Torispherical head
[Flanged and dished]
(ASME VIII Ap.I)
tmin = minimum wall of head, in
P = design pressure, psi
L = inside crown radius, in
S = allowable stress, psi
E = weld joint efficiency factor
PSE
PLt
1.02
885.0min
For t/L 0.002
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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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FLAT HEADS
Flat Heads
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
SE
CPdt
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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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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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PIPING SYSTEMS
ASME B31.1 - ASME B31.3
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 94
ASME B31.1 - ASME B31.3
P = design pressure, psi
D = outside diameter, in
W = longitudinal weld joint efficiency factor
t =wall thickness, in
)(2 PySEW
PDt
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 95
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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Nominal Pipe
Size Outside
Diameter, in.
Schedule Number Wall
Thickness (in)
Inside
Diameter (in)
Weight per
ft (lb)
Weight of
water per ft
(lb)
Moment of
Inertia (in4)
Section Modulus
(in3)
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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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LONGITUDINAL STRESS IN
PIPING SYSTEM The bending stress due to a bending moment M is
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)
Z
Mi75.0S
bending
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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ASME B31.4
OIL - LIQUID PRODUCTS PIPELINES
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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ASME B31.4 - OIL PIPELINES
B31.4
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
S2
PDt
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 103
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)
ksiksiksiksiS
ksix
psi
t
PDS
ksiL
ES
ksipsi
L
EDs
TOTALALLONGITUDIN
PALLONGITUDIN
ALLONGITUDIN
BENDING
4.404.14224
4.14"5.04
"241200
4
2"1200
"6)1030(
3
8
3
8
24)"1200(
"6"24)1030(88
,
,
2
6
2
,
2
6
2
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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ASME B31.8
GAS PIPELINE
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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ASME B31.8 - GAS PIPELINE
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
S2
PDt
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 106
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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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 107
API 579
FITNESS-FOR-SERVICE
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
108
Brittle Fracture
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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API 579 PART 3
ASSESSMENT OF EXISTING
EQUIPMENT FOR BRITTLE FRACTURE
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 110
API 579/ASME FFS PART 3
ASSESSMENT OF EXISTING
EQUIPMENT FOR BRITTLE FRACTURE
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 H2S vapour from nearby paper mill digesters.
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)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 113
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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 114
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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Brittle Fracture
Level 1
compliance with new construction code exemption curves
or impact test requirements
Level 2
include consideration of low stress-based temperature
reduction rules
exemption based on hydrotest
exemption based on service experience
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 116
Assessment Requirements
Summary of repairs and alterations
Past and future operating conditions
Current design pressure, temperature and current wall
thickness
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Data
Determine CET loading-temperature envelope
Potential for autorefrigeration due to depressurization
Shock chilling effects
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 118
LEVEL 1 ASSESSMENT
Figure 3.4M Minimum Allowable Metal Temperature API 579/ASME FFS Page 3-29
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 119
CURVES
A TO D
Assignment Of Materials To The
Material Temperature Exemption
Curves In Figure 3.4
API 579/ASME FFS Page 3-19
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 120
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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 121
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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 122
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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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 123
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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 125
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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 126
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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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.
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 O2 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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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API 579 PART 4
ASSESSMENT OF GENERAL METAL LOSS
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
132
GENERAL METAL LOSS
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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General Corrosion
Based on local thin area assessment rules
Point thickness readings may be used if metal loss
is confirmed to be general
COV
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011
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
135
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 136
Coefficient of Variation
Location Thickness reading
trd, i i=1 to N
(trd, i - tam) (trd, i - tam)2
1
2
3
4
5
We need t and tam (from table 4.2)
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API 579-1/ASME FFS-1 (2007)
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 137
Inspection Summary (table 4.2)
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Use Point Thickness
138
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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Level 1 (cont.)
Based on CTP L=Q(Dtmin)
If s< L, OK for meridional corrosion, check longitudinal corrosion using LTA Level 1 chart
If s>L, use point thickness readings with tam=tmm, or
determine average and minimum thickness for circumferential and meridional directions
determine tam over length L centered on tmm
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 140
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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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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 t
cam
Step 7 - Determine acceptability using Table 4.4
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 (2007)
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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?
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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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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API 579-1/ASME FFS-1 (2007)
Doc. vers. 2009/08/v3.0 Loc:
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EXERCISE
C1 C2 C3 C4 C5 C6 C7 C8
M1 19 19 19 19 19 19 19 19
M2 19 12.2 13.2 14.48 14.22 14.73 15.25 19
M3 19 14.5 15 14 15 15.25 16.76 19
M4 19 15.5 11.9 14.73 9.15 14.73 16.25 19
M5 19 16 15 14.73 14.48 12.2 15.75 19
M6 19 14.48 15 15.49 14.48 14.25 12.45 19
M7 19 19 19 19 19 19 19 19
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
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CORROSION
PROFILE
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API 579-1/ASME FFS-1 (2007)
Doc. vers. 2009/08/v3.0 Loc:
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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 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011 148
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API 579-1/ASME FFS-1 (2007)
Doc. vers. 2009/08/v3.0 Loc:
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Coefficient of Variation Determine the COEFFICIENT OF VARIATION.
If the Coefficient Of Variation (COV) of the thickness readings is greater than 10%,
then use thickness profiles
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 = grid spacing, mm
D = outer diameter, mm
tmin = minimum code required wall, mm
tnom = nominal wall thickness, mm
mmtDtL rdS 38}192;5.16129236.0min{}2;36.0min{ min
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011
mmPSE
PRt 236.13
20686.085.0120658
)0025.0646.0(2068
6.0min
150
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
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API 579-1/ASME FFS-1 (2007)
Doc. vers. 2009/08/v3.0 Loc:
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API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS Ron Frend
Document version 2011/01/v1.4 Last update - 21 Sept 2011
Level 1 STEP 2
STEP - 2. Measure thickness profile.
From the N measurement points ti, determine the minimum measured
thickness tmm
151
19
12.2 11.9
14
9.15
12.2 12.45
19
0
2
4
6
8
10
12
14
16
18
20
1 2 3 4 5 6 7 8
CTP
tmin
API 579-1/ASME FFS-1 FITNESS-FOR-SERVICE OF PIPING, VESSELS AND TANKS