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3/26/2013

Fitness for Service


and API 579
Presented by:
Ray Delaforce

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First consider Unfitness for Service


First consider Unfitness for Service
Here are some of the problems first we consider corrosion
This is generalised corrosion of steel
The red areas are Hematite
The black spots are Magnetite

Red Hematite is flaky and porous. Hematite is the main problem


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First consider Unfitness for Service


First consider Unfitness for Service
This another very typical example

The white flecks are from insulation that has been removed
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First consider Unfitness for Service


First consider Unfitness for Service
This is galvanic corrosion of aluminium and steel in sea water

Note the presence of red Hematite on the steel


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First consider Unfitness for Service


The various mechanisms of Corrosion
 General corrosion
 Occurs over large surfaces
 Generally in the form of Hematite
 Crevice corrosion
 Where crevices give limited access to contained fluid
 Often where parts are fitted together but not welded
 Microbial corrosion
 Caused by microorganisms
 Often producing Hydrogen Sulfide
 Giving rise to accelerated corrosion
 High temperature corrosion
 Causes chemical deterioration
 Causing products that migrate to the grain boundaries

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First consider Unfitness for Service


Consider for a moment the chemistry of corrosion
Take 3 test tubes and set them up in a stand each with a nail
Fill then as follows: 1 tap water, 2 boiled water with at film of
oil as a seal to keep air out, 3 dessicant

The nails in tubes 2 and 3 are the only ones that do not rust
Corrosion requires both Oxygen and Water to produce rust
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First consider Unfitness for Service


Consider for a moment the chemistry of corrosion
Here we have a piece of steel immersed in water
By oxidation, the iron loses 2 electrons
Fe2+ (Iron ion) + 2e-

Fe

At a site in the metal, an Anode is formed with the Iron ions


In the presence of O2, hydroxyl ions are formed
O2

+ 2H2O

+ 4e

4HO

- (OH- is a hydroxyl ion)

The OH- ions and are distributed in the water

OH-

OH-

OH-

OH-

OHFe2+

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anode

First consider Unfitness for Service


Consider for a moment the chemistry of corrosion
Negative OH- ions combine with positive Fe2+ ions, to form
Iron Hydroxide
Fe2+

+ 2OH-

Fe(OH)2

The Iron Hydroxide is deposited on the plate at another site


Forming a Cathode

OH-

OH-

Fe(OH)2

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cathode

OH-

OH-

OHFe2+

anode

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First consider Unfitness for Service


Consider for a moment the chemistry of corrosion
Negative OH- ions combine with positive Fe2+ ions, to form
Iron Hydroxide
Fe2+

+ 2OH-

Fe(OH)2

The Iron Hydroxide is deposited on the plate at another site


Forming a Cathode
The electrons lost by the Iron now migrate through the metal
In the presence of O2 the Iron Hydroxide Oxidises further
4Fe(OH)2 + O2

Fe2O3.H2O

+ 2H2O

Iron Oxide Red Rust

This rust is known as Hematite


Fe(OH)2

OHFe2+

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cathode

anode

We now move on to API 579


What to do when a vessel suffers wear and tear

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We now move on to API 579


After some time in service, a vessel can suffer damage










General corrosion
Pitting corrosion
Grooves and gouging
Surface cracks
Susceptibility to brittle facture
Welding misalignment
Dents
Fire damage

In this presentation we are going to consider just a few of


the effects of wear and tear

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Consider a new cylinder


Look at the requirement per ASME VIII, Division 1
P = 1,5 MPa
D = 1500 mm
c = 3 mm
S = 138 Mpa
E = 0,85

Design pressure
Inside diameter
Corrosion allowance
Allowable (design) stress
Joint Efficiency

According to the code the required thickness is by PV Elite:

If the thickness is below 12,7038 mm there is a code violation


But, that is for new construction so select a 14 mm plate.

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Now consider the same cylinder after


several years service
Some local general corrosion is detected like this

In some locations the thickness is reduced to 11 mm (was 14 mm)


According to the original (new) calculation:





.

The corroded required thickness was 12,7038 3 = 9,7038 mm


The chosen plate thickness was 14 mm
The corroded thickness is still thick enough at 11 mm
Corrosion allowance is reduced to 11 9.7038 = 1,296 mm
BUT: we still need a corrosion allowance of 1,5 mm for future
service !

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Now consider the same cylinder after


several years service
We need 1,5 mm corrosion allowance for the remaining life
The remaining metal available for corrosion is only 1,296 mm
According the original code, we would be in violation !
Remember: The Code is for new construction
Clearly we need additional technical assistance






.

The corroded required thickness was 12,7038 3 = 9,7038 mm


The chosen plate thickness was 14 mm
The corroded thickness is still thick enough at 11 mm
Corrosion allowance is reduced to 11 9.7038 = 1,296 mm
BUT: we still need a corrosion allowance of 1,5 mm for future
service !

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API 579 is the help we need


This is Fitness For Service, and modifies the code requirement
It allows us to use thinner plate, but certain criteria must be met
It provided a procedure to assess the corrosion damage
These are the steps that initially must be followed:
 First a grid must be set over the corroded area
 The at the node points, thicknesses have to be surveyed
 An analysis must be carried out for future service
Then we must consider the future possibilities:






Can vessel be put back into service, or,


Must the operating pressure be reduced
Must the future service life be reduced
Must a repair be carried out
Must the vessel be scrapped !

API 579 can answer these questions


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API 579 Level 1 Assessment


The first step: Survey the corroded area for thickness at the nodes
1 Overlay the corroded area with a grid
2 Label the circumferential and longitudinal lines in the grid
3 Measure the thicknesses at the node points
C1

C2

C3

C4

C5

C6

C7

C8

M1
M2
M3
M4
M5
M6
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M7

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API 579 Level 1 Assessment


Next: Make a table of the thickness measurements inches
1 Find the smallest thickness in the circumferential direction
2 Find the smallest thickness in the longitudinal direction
2 Complete finding the minimum thicknesses in each direction

0.75
0.48
0.55
0.36
0.48
049
0.75
0.75

0.48

0.47

0.55

0.36

0.48

0.49

0.75

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API 579 Level 1 Assessment


Next: Find the absolute smallest thickness tmm
Here is the Critical Thickness Profile (CTP) in the longitudinal direction
We can plot the CTP to find the average thickness

0.75
0.48
0.55
0.36
0.48
049
0.75
0.75

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0.48

0.47

0.55

0.36

0.48

0.49

0.75

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API 579 Level 1 Assessment


Here is the plot of the CTP (critical thickness profile)
This is the grid distance.
Thickness to be used in the assessment tc
tc = Original thickness Corrosion allowance = 0,75-0,1 = 0,65 in
Q = 0,4581 (read from Table 4.5) Now, we need the Critical Length L
L = Q(D.tc)1/2 = 0,4581.(48,2.0.65) =2,564 in (D corroded)

0.55

0.49

0.48

tmm

0.47

0.36

1,5

1,5

1,5

1,5

L
2,564 in

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API 579 Level 2


1 Assessment
Now we need the thicknesses t1 and t2
From the geometry t1 = 0,522 in and t2 = 0,463 in
Find the average thickness tam

(FCA = Future corrosion allowance)

tam = 0,426 in

tam = this shaded area divided by L


tcmin From the code =

P.R
S.E-0,6.P

300.24,1
= 0,430 in
20000.0,85-0,6.300

tam Corroded = tam - FCA = 0,426 0,1

= 0,326 in

Conclusion: Fails Level 1 assessment - try Level 2 assessment


0.55
0.47

t1

tmm

t2

0.49

0.48

FCA

0.36
tam

1,5

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1,5
L
2,564 in

1,5

1,5

20

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API 579 Level 2 Assessment


We have already computed the corroded average thickness:
tam Corroded = tam - FCA = 0,426 0,1

= 0,326 in

We need the Remaining Allowable Strength Factor


This is normally taken as

RSFa

RSFa = 0,9

The calculated required thickness (code formula) tcmin = 0,430 in


Now:

RFSa x tcmin = 0,9 x 0,430

= 0,387 in

The remaining thickness Fails Level 2


We can drop the MAWP of the component

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API 579 Reduced MAWP


We have already computed the corroded average thickness:
tam Corroded = tam - FCA = 0,426 0,1
MAWP =

t.S.E
=
R+0,6.t

0,326.20000.0,85
24,1+0,6.0,326

= 0,326 in
= 228,1 psi

Thus the MAWP has to be reduced from 300 psi to 228,1 psi
This method used the formal grid, but we can take random points

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API 579 Consider Random Points


First, we make a table of the random point thicknesses
Next we compute the average thickness
tam =

1
N

(trd)
i =1

= 12,0667 mm

Next we compute (trd tam) for each point


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API 579 Consider Random Points


First, we make a table of the random point thicknesses

Next we compute (trd tam) for each point


Then compute
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(trd tam)2 for each point


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API 579 Consider Random Points


First, we make a table of the random point thicknesses
Find the value S

Next we compute (trd tam) for each point


Then compute

(trd tam)2 for each point

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API 579 Consider Random Points


First, we make a table of the random point thicknesses
Find the value S
N

S = (trd-ta,)2
i =1

= 12,9333 mm

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API 579 Consider Random Points


Now compute the Coefficient Of Variance COV
COV =

1
1
[ S ] 0,5 =
tam N-1
12,0667

[ 12,9333
]
14-1

0,5

= 0,080 or 8%
Because COV is less than 10% we can use the average thick. tam
Now the original nominal thickness

tnom = 16 mm

LOSS is the amount of corrosion that has already taken place


tnom - tam= 16 12,0667 = 3,9333 mm

LOSS

We now have to use code formula to compute required thickness

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API 579 Consider Random Points


This is the cylinder we with which are dealing
P
D
S
E
c
tnom

= 3,85 MPa
= 484 mm
= 96,196 MPa
= 1,0
= 2 mm
= 16 mm

Current MAWP
Inside diameter
Allowable design stress
Joint Efficiency
Corrosion allowance Also FCA
Actual new thickness of the cylinder

From the code formula:


3,85.(242+2+3,9333)
P.(R+c+LOSS)
tcmin =
=
96,196.1,0-0,6.3,85
S.E-0,6.P
tam FCA = 12,0667 2,0

= 10,1670 mm
= 10,0667mm

The cylinder is not thick enough for future service per Level 1
We can:
 Reduce the MAWP, or,
 Reduce the future corrosion allowance (FCA)
 Try Level 2 assessment
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API 579 Consider Random Points Level 2


We already know the

tam FCA = 10,0667 mm

The minimum measured thickness

tmm- FCA = 8 mm

tlim = max(0,2.tnom; 2,5) = max(0,2.16; 2,5)

= 3,2 mm

Compute max(0,5.tcmin ; tlim) = max(0,5.10,167; 3,2)


= 5,0835 mm
Level 2 assessment passes

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Simple calculation Remaining Life


Suppose we have the following data over a period of 5 years
 The total uniform corrosion is 2,5 mm for the 5 years
 We need to know the remaining life of a head
This is the head whose remaining life we require:
P
D
c
S
E

= 1,5 MPa
= 2500 mm
= 3 mm
= 120 Mpa
= 1,0

MAWP if the head


Original Diameter (New)
Original corrosion allowance
Design stress of the material
Joint efficiency

Uniform corrosion rate = 2,5 / 5 = cRate = 0,5 mm per year


tFinal =
t

P.D
2SE0,2P

1,5.2500
2.120.1,00,2.1,5

= Current corroded thickness

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= 15,645 mm
= 20 mm

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Simple calculation Remaining Life


tFinal = 15,645 mm, and t = 20 mm and cRate = 0,5 per year
Remaining corrosion = 20 - 15,645 = 4,355 mm
Remaining life = 4,355 / corrosion rate = 4,355 / 0,5 = 8,71 years
This assumes the corrosion continues at a uniform rate
We move onto something else now

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Simple Example Pitting Corrosion


This is a typical example of pitting corrosion

The Level 1 assessment is very simple

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Simple Example Pitting Corrosion


First, we get the data for the cylinder original design
D
tnom
LOSS
FCA
S
E

=
=
=
=
=
=

60 in
0,75 in
0,05 in
0,07 in
17500 psi
0,85

Inside diameter
Original thickness
Uniform metal loss so far
Future corrosion allowance
Design stress
Joint Efficiency

Step 1: Find the worst the area with the highest number of pits
Step 2: Measure maximum pit depth wmax = 0,3 in
Step 3: Get the value tc from this equation
tc = tnom LOSS FCA = 0,75 0,05 0.07 = 0,63 in
Step 4: Get the remaining thickness ratio Rwt from this equation
Rwt =

tc + FCA-wmax
tc

0,63 + 0,07-0,3
= 0,6349
0,63

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Simple Example Pitting Corrosion


tc = 0,63 in

Rwt = 0,6349

LOSS = 0,05 in

FCA = 0,07 in

Step 5: Get the effective inside radius of the shell Rc


Rc = D/2 + LOSS + FCA = 30+0,05+0,07 = 30,12 in
Step 6: Compute the MAWP of the cylinder
S.E.tc
MAWP =
Rc+0,6.tc

17500.0,85.0,63
30,12+0,6.0,63

= 307 psi

Step 7: Check to see if the MAWP has to be reduced

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Simple Example Pitting Corrosion


Here is an example of a pit measuring guage

We move on to a new subject


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Out of Roundness - Peaking


This is what is meant by peaking:
The ends of the cylinder at straight instead of cylindrical
Measure the peak height

= 0,31 in

We perform a Level 2 assessment

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Out of Roundness - Peaking


Get all the data for this cylinder
Do = 36 in
tnom = 0,5 in
P
= 315 psi
E
= 1,0
FCA = 0,05 in
EY = 25,2.106 psi
Sa = 16 800 psi
Hf = 3,0

cylinder outside diameter


wall thickness
design pressure
joint efficiency
future corrosion allowance
Elastic Modulus
design stress
factor for secondary stress from API 579

LOSS= 0 in

metal lost so far

0,31 in

0,5 in

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36 in

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Out of Roundness - Peaking


Get all the data for this cylinder
Do = 36 in
tnom = 0,5 in
P
= 315 psi
E
= 1,0
FCA = 0,05 in
EY = 25,2.106 psi
Sa = 16 800 psi
Hf = 3,0

cylinder outside diameter


wall thickness
design pressure
joint efficiency
future corrosion allowance
Elastic Modulus
design stress
factor for secondary stress from API 579

LOSS= 0 in

metal lost so far

Wall thickness to be used in the assessment


tc = tnom LOSS FCA = 0,5 0,0 0,05
Get the current membrane stress from the Code
m =

P.(Ro- 0,4.tc)
tc.E

315(18 - 0,4.0,45)
0,45.1,0

R internal radius = Ro tnom + FCA + tc/2


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tc
= 0,45 in
m
= 12 474 psi
= 17,775 in
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Out of Roundness - Peaking


Induced extra bending stress ratio SP

is Poissons Ratio = 0,3


12(1- 2)PR3 0,5
SP = (

EY.tc3

=(

12(1- 0,3 2)315.17,7753 0,5


)
25,5.106.0,453

= 2,88
From SP and /R and

Figure 8.13 to get

Cf = 0,83

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Out of Roundness - Peaking


Induced extra bending stress ratio SP

is Poissons Ratio = 0,3


12(1- 2)PR3 0,5
SP = (

EY.tc

=(

12(1- 0.3 2)315.17,7753 0,5


)
25,5.106.0,453

= 2,88
From SP and /R and

Figure 8.13 to get

Cf = 0,83

We need 3 other values: Rb1, Rb2 and Rbs the calculation is long
Rb1 = 3,43,

Rb2 =3,43 and

Rbs = -1,0 (no calculation shown)

Finally, compute the Remaining Strength Factor RSF


RSF = min(

Hf.Sa
m.(1+Rb1)+LOSS(1+Rbs)

3,0.16 800
= min(
; 1,0 )
12,474.(1+3,43)+0
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; 1,0)

= 0,91
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Out of Roundness - Peaking


RSF = 0,91 from the previous slide
RSF allowed = 0,90 API 579 requirement
Conclusion: passed, cylinder can be put into service

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A word or two about grooves


A groove can be thought of as a blunt crack in the vessel
This can be analysed mathematically (modeled as) as a half ellipse
The two important dimension are: crack length a, and tip radius r
Adjacent to the edge of the crack, the stresses increase
Sa is the average stress, and Sc is the increased stress
Sa / Sc is known as the Stress Concentration Factor (scf)
Sc

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Sa

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A word or two about grooves


A Cambridge researcher, Inglis did the mathematical work
This is the equation he devised for the scf
scf = 2 +

ar

If the crack tip has a very sharp radius, the scf if very high
The stress can be in the Plastic range of the stress-strain diagram

Sc

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Sa

43

A word or two about grooves


A Cambridge researcher, Inglis did the mathematical work
This is the equation he devised for the scf
scf = 2 +

ar

If the crack tip has a very sharp radius, the scf if very high
The stress can be in the Plastic range of the stress-strain diagram
This can be a source of fatigue problems
elastic
range

plastic range

stress

Yield point

0,2%

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strain
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3/26/2013

A word or two about grooves


A Cambridge researcher, Inglis did the mathematical work
This is the equation he devised for the scf
scf = 2 +

ar

If the crack tip has a very sharp radius, the scf if very high
The stress can be in the Plastic range of the stress-strain diagram
This can be a source of fatigue problems
We have not analysed grooves and pitting
This is the end of the presentation

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