Fitness for Service

IN THE CASE OF A NEW VESSEL WE

CAN DESIGN IT TO A CODE

IN-SERVICE VESSEL THAT IS

CORRODED – WHAT DO WE DO

THIS IS A PUBLIC SAFETY ISSUE

Examples of In-Service Defects

Corrosion Corrosion

Corrosion Pitting
Images from www.materialsengineer.com

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 STATED OBJECTIVES

Quantitative engineering evaluations which are

performed to demonstrate the structural integrity of
an in-service component containing a flaw.

API RP 579 Flaw Coverage

• Brittle Fracture – Section 3
• General Metal Loss – Section 4
• Local Metal Loss – Section 5 Section 4, 5 & 6 are
• Pitting Corrosion – Section 6 currently available in
CodeCalc (and PVElite)
• Blisters – Section 7
• Weld Misalignment and Shell Distortions – Section 8
• Crack-like Flaws – Section 9
• Creep Damage – Section 10
• Fire Damage – Section 11

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 General FFS Procedures
• Identify flaw type and damage mechanism
• Check applicability and limitations of the specific flaw
type procedure.
• Review data requirement and gather the data.
• Apply the assessment techniques and compare the
results to the acceptance criteria.
• Estimate remaining life for the inspection interval.
• Apply remediation as appropriate.
• Apply in-service monitoring as appropriate.
• Document the results

Level of Assessment
• Level 1 – Simplified methods using charts and
conservative assumptions.

• Level 2 – More detail evaluations with less-conservative

results.

• Level 3 – Uses more sophisticated methods such as

FEA.

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 API 579 – Example 4.11

Pressure Vessel Information:

Design Conditions = 300 psig @ 350 OF

Inside (new) Diameter = 48 inches D

Nominal Thickness = 0.75 inches

Uniform Metal Loss = 0 inches (no general corrosion)

Future Corrosion Allowance = 0.10 inches FCA

Material = SA 516 Grade 70

Joint Efficiency = 0.85

PERFORM THE INITIAL CALCULATIONS

CALCULATE THE MINIMUM REQUIRED THICKNESS:

Using the ASME VIII, Division 1 Code

In the Circumferential (hoop) Direction
P x ( R + FCA )
tCmin =
SE – 0.60 x P

300 x ( 24 + 0.10 )
= = 0.492 inches
17500 x 0.85 – 0.60 x 300

In the Longitudinal ( axial ) Direction

P x ( R + FCA )
tLmin =
2SE + 0.40 x P

300 x ( 24 + 0.10 )
= = 0.242 inches
2 x 17500 x 0.85 + 0.40 x 300

tmin = Max ( tCmin, tLmin) = 0.492 inches

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 WE NOW KNOW THE REQUIRED MINIMUM THICKNESS

This thickness which is tmin = 0.492 inches

We must now consider the actual current condition of the vessel wall to
assess its future use

During a routine inspection, an area of corrosion is found

WHAT DO WE DO NOW ?

1 we determine the area of this corrosion

2 we measure the various thicknesses in this area

3 let us now see how we do this

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 SURVEY METHOD

1 Find the corrosion area – Identify it

2 Overlay a Grid with nodes at the intersections 1.5 inches pitch
3 Label the grid Circumferential and Longitudinal Gridlines
4 Measure thicknesses at every NODE – tabulate the results

C1 C2 C3 C4 C5 C6 C7 C8

M1

M2

M3

M4

M5

M6

M7

NOW TABULATE THE VALUES

1 Set out the table of node thicknesses
2 Find the CTP for the Circumference Thicknesses

3 Find the CTP for the Longitudinal Thicknesses

4 Complete the CTP values
5 Determine minimum thickness tmm = 0.36 inches

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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 WE NOW HAVE THE COMPLETED CTP TABLE

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

Minimum measured thickness tmm = 0.36

CONTINUE WITH THE CALCULATION

Find the Remaining Thickness Ratio (Rt):

tmm - FCA 0.36 - 0.10
Rt = = = 0.528
tmin 0.492
Allowable Remaining Strength Factor (RSFa):

Section 2.4.2.2(d) states: “Recommended value for

RSFa is 0.90 … which is conservative…..”

RSFa = 0.90

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 CONTINUE WITH THE CALCULATION

Remaining Thickness Ratio Rt = 0.528

Allowable Remaining Strength Factor RSFa = 0.90
Calculate the ‘Q’ factor (or read from Table 4.4):

1 - Rt
Q = 1.123 [( )2 - 1 ]0.5
1 - Rt / RSFa

1 - 0.528
= 1.123 [( )2 - 1 ]0.5
1 - 0.528 / 0.90

= 0.619

CONTINUE WITH THE CALCULATION

Remaining Thickness Ratio R = 0.528

Allowable Remaining Strength Factor RSFa = 0.90
Factor Q = 0.619
Calculate Length for thickness averaging (L):

L=Q D x tmin

= 0.619 48 x 0.492

= 3.0 inches

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 CONTINUE WITH THE CALCULATION

Remaining Thickness Ratio R = 0.528

Allowable Remaining Strength Factor RSFa = 0,90
Factor Q = 0.619
Length for thickness averaging L = 3.0 inches

Longitudinal Critical Thickness Profile CTP

FCA

tmin = 0.492”
L

s = flaw dimension
Flaw dimension s = 8.71 inches
L is considered for the 3 thinnest points (see later)

CONTINUE WITH THE CALCULATION

Remaining Thickness Ratio R = 0.528

Allowable Remaining Strength Factor RSFa = 0.90
Factor Q = 0.619
Length for thickness averaging L = 3.011 inches
Flaw dimension s = 8.71 inches

We need not consider the Circumferential CTP because

tLmin < tmm - FCA
0.242” < 0.36” - 0.10” ( = 0.26”)

We are now only concerned with the profile within the

flaw distance L taking the three thinnest adjacent points

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 CONTINUE WITH THE CALCULATION

Length for thickness averaging L = 3.0 inches

Divide into equal slices using the Grid Pitch
Dimension the L length and pitches

Longitudinal Critical Thickness Profile (CTP) within length L

0.48 0.49
0.55 tmm
0.47 0.36

1,5” 1,5” 1,5” 1,5”

L = 3.0”

CONTINUE WITH THE CALCULATION

Longitudinal Critical Thickness Profile (CTP) within length L
0.48 0.49
0.55 tmm
0.47 0.36

1,5” 1,5” 1,5” 1,5”

L = 3.0”
Calculate the Average Thickness (tam) over length L
This is done by taking the area and dividing by L:
(0.55 + 0.36 + 0.36 + 0.48) x 1.5
tam = = 0.438 inches
2 x L ( = 3.0)

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 CONTINUE WITH THE CALCULATION
Per paragraph 4.4.2.1.f.1:

tam - FCA = 0.438 - 0.10 = 0.338 inches

tCmin = 0.492 inches
tam - FCA > tCmin is FALSE

Per paragraph 4.4.2.1.f.2:

tmm - FCA = 0.36 - 0.10 = 0.26 inches

Max(0.5tmin, 0.10) = Max(0.246, 0.10) = 0.246 inches
tmm - FCA > Max(0.246, 0.10) is TRUE

BECAUSE ONE CONDITION IS FALSE, LEVEL 1

ASSESSMENT CRITERIA ARE NOT SATISFIED !

CONTINUE WITH THE CALCULATION

BECAUSE ONE CONDITION IS FALSE, LEVEL 1
ASSESSMENT CRITERIA ARE NOT SATISFIED !

We can derate the MAWP based on Level 1 assessment

Using the formula in ASME for pressure:

Set t = tam - FCA in the equation = 0.338 inches

SEt
MAWP =
Rc + 0.60.t
17500 x 0.85 x 0.338
=
24.10 + 0.60 x 0.338
= 207 psi

Therefore MAWP is derated from 300 psi down to 207 psi

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 CONTINUE WITH THE CALCULATION
Therefore MAWP is derated from 300 psi down to 207 psi

This is based upon the LEVEL 1 assessment !

WE CAN PERFORM A LEVEL 2 ASSESSMENT TO

PERFORM A MORE DETAILED ANALYSIS

Per paragraph 4.4.3.2.1.a.1:

tam - FCA = 0.438 - 0.10 = 0.338 inches
RSFa x tCmin = 0.90 x 0.492 = 0.443 inches
tam - FCA > RSFa x tCmin is FALSE
Per paragraph 4.4.3.2.1.b:
tamm - FCA = 0.36 - 0.10 = 0.260 inches
Max(0.5.tmin, 0,1) = Max(0.246, 0.1) = 0.246 inches
tamm - FCA > Max(0.5.tmin,0.1) is TRUE

CONTINUE WITH THE CALCULATION

Because LEVEL 2 assessment criteria are not met, we

must re-evaluate the MAWP according to LEVEL 2
requirements.

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 CONTINUE WITH THE CALCULATION
We can derate the MAWP based on Level 2 assessment
Using the formula in ASME for pressure:

Set tc = (tam - FCA) / RSFa in the equation

= (0.438 - 0.10) / 0.90 = 0.376 inches
SEtc
MAWP =
Rc + 0.60.tc
17500 x 0.85 x 0.376
=
24.10 + 0.60 x 0.376
= 230 psi

Therefore MAWP is derated from 300 psi down to 230 psi

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