Part 4: Assessment of general metal loss

Thickness Averaging Approach Used For the Assessment:

The assessment procedures in this Part are based on a thickness averaging approach. If local areas of metal loss are found
in the component, the thickness averaging approach may produce conservative results. For these cases, the assessment
procedures of Part 5 can be utilized to reduce the conservatism in the analysis. The exact distinction between uniform
and local metal loss cannot be made without knowing the characteristics of the metal loss profile. For most evaluations, it
is recommended to first perform an assessment using Part 4.

Applicability and Limitations of the Procedure

General Metal Loss Assessment

The assessment procedures in this Part can be used to evaluate general metal loss (uniform or local) that exceeds or is
predicted to exceed the corrosion allowance before the next scheduled inspection. The general metal loss may occur on
the inside or outside surface of the component. Assessment procedures based on point thickness readings and thickness
profiles are provided. The assessment procedure to be used in an evaluation depends on the type of thickness data
available, i.e. point thickness readings or thickness profiles, the characteristics of the metal loss (i.e. uniform or local), and
the degree of conservatism acceptable for the assessment. The methodology shown below can be used to determine the
assessment procedure to be used in the evaluation.

Calculation of the MAWPr and MFHr and Coincident Temperature

Calculation methods are provided to rerate the component if the acceptance criteria in this Part are not satisfied. For
pressurized components, the calculation methods can be used to find a reduced maximum allowable working pressure
( MAWPr ) and coincident temperature. For tank components (i.e. shell courses), the calculation methods can be used to
determine a reduced maximum fill height ( MFHr ) and coincident temperature.

Definition of Component Types

In this Part, the following component definitions are used in determining the permissible assessment level for a
component.

Type A Components

– A component that has a design equation that specifically relates pressure (or liquid fill height for tanks) and
supplemental loads, as applicable, to a required wall thickness, and the supplemental loads in combination with pressure
do not govern the required wall thickness, i.e. the

required thickness is based on pressure only. Examples of Type A components are shown below.

• Pressure vessel cylindrical and conical shell sections with dimensions that satisfy the criteria in Figure 4.3 and Figure 4.4.
• Spherical pressure vessels and storage spheres.

• Spherical, elliptical and torispherical formed heads.

• Straight sections of piping systems and elbows or pipe bends that do not have structural attachments that satisfy the
temperature criteria in Figure 4.5.

• Cylindrical atmospheric storage tank shell courses.

Type B Components

There are two classes of Type B Components.

Type C components

Applicability of the Level 1 and Level 2 Assessment Procedures

The Level 1 or 2 assessment procedures in this Part apply only if all of the following conditions are satisfied.

a) The original design criteria were in accordance with a recognized code or standard (see Part 1, paragraphs 1.2.2 or
1.2.3).

b) The region of metal loss has relatively smooth contours without notches, i.e. negligible local stress concentrations.

c) The component is not in cyclic service. If the component is subject to less than 150 cycles, i.e. pressure and/or
temperature variations including operational changes and start-ups and shut-downs, throughout its previous operating
history and future planned operation, or satisfies the cyclic service screening procedure in Part 14, then the component is
not in cyclic service.

d) The following limitations on component types and applied loads are satisfied: 1) Level 1 Assessment – Type A
Components (see paragraph 4.2.5) subject to internal pressure or external pressure. 2) Level 2 Assessment – Type A and
Type B Components (see paragraph 4.2.5) subject to internal pressure, external pressure, supplemental loads (see Annex
2C, paragraph 2C.2.7) or any combination thereof.

e) The Level 1 or Level 2 assessment procedures may be applied if the region of metal loss is located a distance Lmsd from
the Type C component (see Figure 4.6).

Applicability of the Level 3 Assessment Procedures

A Level 3 Assessment can be performed when the Level 1 and 2 Assessment procedures do not apply, or when these
assessment levels produce overly conservative results, i.e. would not permit operation at the current design conditions.
Examples include, but are not limited to the following.

a) Type A, B, or C Components subject to internal pressure, external pressure, supplemental loads, and any combination
thereof.

b) Components with a design based on proof testing, e.g. piping tee or reducer produced in accordance with ASME B16.9
where the design may be based on proof testing.

c) Components in cyclic service or components where a fatigue analysis was performed as part of the original design
calculations; the assessment should consider the effects of fatigue on the FFS calculations used to qualify the component
for continued operation.
Data Requirements

Required Data/Measurements for a FFS Assessment

The general metal loss may occur on the inside or outside surface of the component.

Assessment procedure based on point thickness reading and thickness profiles are provided:

Two options for obtaining thickness data are presented:

1) Point thickness readings – point thickness readings can be used to characterize the metal loss in a component
if there are no significant differences in the thickness reading values obtained at inspection monitoring locations.
2) Thickness profiles – thickness profiles should be used to characterize metal loss in a component if there is a
significant variation in the thickness readings. In this case, the metal loss may be localized, and thickness profiles
(thickness readings on a prescribed grid) should be used to characterize the remaining thickness and size of the region
of metal loss.

The thickness quantities used in this Part for the assessment of general metal loss are the average measured thickness
and the minimum measured thickness. If thickness readings indicate that the metal loss is general, the procedures in this
Part will provide an adequate assessment. However, if the metal loss is localized and thickness profiles are obtained, the
assessment procedures of this Part may produce conservative results, and the option for performing the evaluation using
the assessment procedures of Part 5 is provided.

 If point thickness readings are used in the assessment, the assumption of uniform metal loss should be
confirmed.

a) Additional inspection may be required such as visual examination, radiography or other NDE methods.

b) A minimum of 15 thickness readings should be used unless the level of NDE utilized can be used to confirm that the
metal loss is general. In some cases, additional readings may be required based on the size of the component, the
construction details utilized, and the nature of the environment resulting in the metal loss. A sample data sheet to record
thickness readings is shown in Table 4.2.

c) If the Coefficient Of Variation (COV) of the thickness readings is greater than 10%, then thickness profiles shall be
considered for use in the assessment. The COV is defined as the standard deviation divided by the average. A template
that can be used to compute the COV is provided.

trd: uniform thickness away from the local metal loss location established by thickness measurements at the time of the
assessment.

tam: average measured wall thickness of the component based on the point thickness readings (PTR) measured at the
time of the inspection
  If thickness profiles are used in the assessment, the following procedure shall be used to determine the
required inspection locations and the Critical Thickness Profiles (CTPs).
a) STEP 1 – Locate the region of metal loss in the component and determine the location, orientation, and length
of the inspection plane(s).
b) STEP 2 – To determine the inspection plane(s) for thickness readings the following shall be considered: