API 579-1 Fitness-For-Service Assessment

Plant ID: Meren PP

Equipment Number: ABC-1234 Equipment: Test Separator
Equipment Type: Pressure Vessel Date: 25th March 2015
1 Introduction
The following Level 1 and Level 2, Fitness-For-Service assessment was carried out in accordance with:
API 579-1 Part 13, for pressurized components with laminations, excluding HIC or SOHIC damage.

Review of the process operating conditions indicate that the vessel is not operating in the creep range, that is, the
design temperature is less than the temperature limit specified in API 579-1, Part 4, Table 4.1. and that the vessel
has sufficient material toughness for design conditions.

The vessel which was constructed to ASME VIII, Div. 1 rules, is not in cyclic service and the shell is a Type 'A'
Component as defined in API-579-1, Part 4, paragraph 4.2.5.

2 Summary
Both the Level 1 and Level 2 assessment criteria are not satisfied as the the lamination is in close proximity to a
major structural discontinuity (a structural support); see STEP 6, part 4 of this assessment for details. As per
Appendix 1 and API 579-1, 13.2.5.2, a Level 3 Fitness-For-Service assessment for laminations shall be performed .

3 Contents
1 Introduction
2 Summary
3 Contents
4 Nomenclature
5 Vessel Data
6 Level 1 and 2 Assesment per API 579-1, Part 13
7 Figure 1 - Typical Lamination
Figure 2 - Weld Joint Spacing and Multiple Laminations
8
9 Figure 3 -
10 Figure 4 -
11 Test Separator Pictures
12 Appendix 1 - Overview of the FFS Assessment Procedure

4 Nomenclature

2a depth of through-wall embedded crack associated with a lamination

c lamination dimensions in the circumferental direction
2c length of through-wall embedded crack associated with a lamination
CTP critical thickness path
CL test separator centre line at the 6 o'clock position
D shell inside diameter
E weld joint efficiency
FCA future corrosion allowance
FFS Fitness-For-Service
HIC hydrogen inducted cracking
IR Visions integrity report
Lh lamination height
Lmsd spacing to the nearest major structural discontinuity
 Ls lamination-to-lamination spacing
Lw spacing to nearest weld joint
LOSS amount of uniform metal loss at the time of the assessment.
MAWP maximum allowable working pressure
MAWPC maximum allowable working pressure based on circumferential stress
P internal design pressure
PAUT phased array ultrasonic testing
R inside radius corrected for LOSS and FCA as applicable
RAT rope access team
s lamination dimension in the longitudinal direction
S allowable stress
SOHIC stress-orientated hydrogen induced cracking
tcmin average measured wall thickness of the component based on the circumferential CTP determined at the
time of the inspection.
tc corroded wall thickness, allowing for future corrosion loss
tmin minimum required wall thickness of the component (see API 579-1, Annex A, paragraph A.2)
t C
min minimum required thickness of a conical or cylindrical shell based on the stresses in the circumferential
or hoop direction (see API 579-1, Annex A, paragraph A.2)
tLmin minimum required thickness of a conical or cylindrical shell based on the stresses in the longitudinal
direction (see API 579-1, Annex A, paragraph A.2)
tmm minimum measured thickness determined at the time of the inspection
tnom nominal or furnished thickness of the component adjusted for mill undertollerance as applicable
trd uniform thickness away from the local metal loss location established by thickness measurements at the
time of the assessment.
UT ultrasonic testing
5 Vessel Data
Material: SA-516 Grade 70, Year 1967
Allowable Stress In Tension (S): 17500 psi
Design Pressure (P): 500 psig @ 100 ⁰F
Inside Diameter (D): 34 in
Inside Radius (R): 17.125 in (with metal loss and FCA applied)
Corrosion Allowance (FCA): 0.125 in
Weld Joint Efficiency (E): 0.85
Nominal Thickness (tnom): 1.000 in
Uniform Thickness Away From
Local Metal Loss (trd): 1.006 in
LOSS: 0.00 in
tcmin: 0.586 in (A.12)

6 Perform a Level 1 and 2 Assesment per API 579-1, Part 13.

a)
STEP 1 – Determine if there is any surface bulging on either the inside or the outside surface of the
component at the location of the lamination. If there is surface bulging, then evaluate the lamination the
lamination as a blister using the Level 1 Assessment method in API 579-1 Part 7.
Does the inspection report indicate surface bulging on either the inside or outside surface of the
component at the location of the lamination:
Lamination 1: No
(b) STEP 2 - Determine the information in paragraph 13.3.3.1:

Table1: Size, Location and Spacing for Laminations

Data required for Level 1 and Level 2 Assessment
Lamination Identification 1 2 3 4
Dimensions s (1) (3) 12.023 in
Dimensions c (1) (3) 13.809 in
Lamination Height Lh (1) 0.018 in
Edge-to-Edge Spacing to the nearest lamination Ls (2) 100.0 in (4)
Minimum Measured Thickness tmin (1) 0.473 in
Spacing to the Nearest Weld Joint Lw (2) (3) 39.0 in
Spacing to the Nearest Structural Discontinuity Lmsd (2) (3) 5.992 in
Surface Bulging Present No
Through-Wall Cracking (Yes/No) No
Internal Metal Loss at Lamination Location 0.0 in
Are there two or more laminations at different depths No Total : 1
Are both laminations on the same plane N/A
Notes:
1. See Figure 1 3. See Figure 4
2. See Figure 2 4. Arbitrarily large value as only one lamination was found in the area inspected

(c) STEP 3 – If there are two or more laminations on the same plane, there is no indication of through
thickness cracking, and the spacing does not satisfy Equation (13.1), then the laminations shall be
combined into a single larger lamination in the assessment.
If there are two or more laminations at different depths in the wall thickness of the component and the
spacing does not satisfy Equation (13.1), then the group of laminations shall be evaluated as equivalent
HIC damage using the Level 1 Assessment method in Part 7. In applying this criterion, the spacing shall be
measured parallel to the wall thickness. Applying Equation (13.1):

Ls > 2tc

2tc = 2(trd - FCA)

= 1.762 in
Ls = 100.0 in (arbitrarily large value as only one lamination found in the area inspected)
Is Ls > 2tc ? YES

Equation (13.1) is satisfied.

Are there two or more laminations on the same plane: NO

Is there any indication of through wall thickness cracking: NO

(d) STEP 4 – If Equation (13.2) is satisfied, proceed to STEP 5; otherwise, evaluate the through-thickness
component of the lamination as a crack-like flaw using the Level 1 Assessment method in Part 9. In this
evaluation, the crack depth shall be equal to 2a = Lh and the crack length shall be equal to:

2c = max[s,c]

Applying Equation (13.2):

Lh ≤•max[s,c]

1) Lamination 1
 0.09•max[s,c] = 1.243 in
Lh = 0.018 in
0.018 ≤ 1.243 in

Equation (13.2) is satisfied for lamination 1.

(e) STEP 5 – Determine the wall thickness to be used in the assessment using Equation (13.3) or Equation
(13.4), as applicable. Applying Equation (13.3):
tc = tnom - LOSS - FCA

tc = tnom - LOSS - FCA = 0.875 in

Equation (13.4) may also be applied:

tc = trd - FCA = 0.881 in

(f) STEP 6 – If all of the following conditions are satisfied, proceed to STEP 7; otherwise, the lamination is not
acceptable per the Level 1 Assessment procedure.

1) The inspection report indicates no evidence of through-thickness cracking.

2) The lamination is not surface breaking in accordance with Equation (13.5):

tmm ≥ 0.10tc

i) Lamination 1
0.10 tc = 0.0881 in
tmm = 0.473 in
0.473 ≥ 0.0881 in

Equation (13.5) is satisfied for lamination 1.

3) The distance between any edge of the lamination and the nearest weld seam satisfies Equation
(13.6):
Lw ≥ max[2tc, 1.0 in]

2tc = 1.762 in from Equation (13.1)

i) Lamination 1
Lw = 39.0 in
max[2tc, 1.0 in] = 1.76 in
39.0 ≥ 1.76 in

Equation (13.6) is satisfied for lamination 1.

4) The distance from any edge of the lamination to the nearest major structural discontinuity satisfies
Equation (13.7):
Lmsd ≥ 1.8 √(Dtc)

1.8 √(Dtc) = 9.85 in

i) Lamination 1
Lmsd = 5.992 in
5.992 < 9.85 in
 Equation (13.7) is not satisfied for lamination 1.

5) If the lamination is in hydrogen charging service, then the planar dimensions of the lamination
satisfy Equations (13.8) and (13.9):
s ≤ 0.6 √(Dtc)
c ≤ 0.6 √(Dtc)

Review of process operating conditions indicates the vessel is not in hydrogen service.

(g) STEP 7 – Determine the MAWP for the component (see Annex A, paragraph A.2) using the thickness from
STEP 5.

This step is not applicable if STEP 6 fails, but has been included for reference.

In calculating the component MAWP, P ≤ 0.385SE and tcmin ≤ 0.5R (Longitudinal Joints), and
supplimental loads are negligible, so Equation (A.10) pertains.

Is P ≤ 0.385SE ? YES Is tcmin ≤ 0.5R ? YES

0.385SE = 5653 psi tcmin = 0.586
P= 500 psi 0.5R = 8.563 in

Lamination 1
S = 17500 psi
E = 0.85
tc = 0.8810 in
R = 17.1250 in

𝑀𝐴𝑊𝑃𝐶=
𝑆𝐸𝑡𝑐/(𝑅+0.6𝑡𝑐)= 742.33 psig

Figure 1 - Typical Lamination

A A

Periphery of
Lamination Lamination Plan View Lamination
 tmm

tc Lh

s or c

Section A-A
Cross Section of Lamination

Figure 2 - Weld Joint Spacing and Multiple Laminations

Lamination 1 Lamination 2

c2
Ls

Lw
c1

s1 s2

a) Planar View of Laminations Close to a Weld Seam and to Other

Laminations

Lw s1 s2

a) Cross Sectional View of Laminations Close to a Weld Seam and

to Other Laminations

Appendix 1

Obtain
Equipment Data
 Obtain
Equipment Data

Perform a Level 1
Assessment

Yes Equipment is
Acceptable per
Level 1 Criteria?

No

Perform a Level 2 No
Assessment

Yes
Perform a Level 3 No
Assessment?

Yes Equipment No
Acceptable per Level 2 Yes
Assessment?

Equipment No No
Acceptable per Level 3 Rerate Equipment?
Assessment?
Yes
Yes
Determine Remaining Life -
Perform Rerate per
Establish In-Service
Monitoring Program if Level 3 Criteria to
Reduce Pressure
Necessary, Develop an
and/or Temperature
Inspection Plan

Return the Yes No Repair, Replace

Equipment to Remaining Life or Retire
Service Acceptable? Equipment

Overview of the FFS Assessment Procedure to Evaluate a Component with Laminations (API 579-1 Figure 13.1)

Rev: 0 Name Position Date

Prepared by: 25th March 2015
Reviewed by: 25th March 2015
 API 579-1 Fitness-For Service Assessment
Plant ID A Plant
Equipment Number: ABC-1234 Equipment: Test Separator
Equipment Type: Vessel Date: 17th March 2015

Introduction
The following Level 2, Fitness-For-Service assessment was carried out in accordance with API 579-1, Part 13, for
pressurized components with laminations excluding HIC or SOHIC damage. Inspection of this pressure vessel,
constructed to ASME Section VIII, Div.1 rules, located two laminations in the shell. Review of the process operating
conditions indicate that the vessel is not operating in the creep range, that is, the design temperature is less than the
temperature limit specified in API 579-1, Part 4, Table 4.1. and the vessel has sufficient material toughness for design
condition. The vessel is not in cyclic service and the shell is a Type 'A' Component as defined in API-579-1, Part 4,
paragraph 4.2.5.

Summary
The Level 1 assessment criteria are/are not satisfied
The Level 2 assessment criteria are/are not satisfied.

Nomenclature
2a depth of through-wall embedded crack associated with a lamination
c lamination dimensions in the circumferental direction
2c length of through-wall embedded crack associated with a lamination
D shell inside diameter
E weld joint efficiency
FCA future corrosion allowance (see API 579-1, Annex A, paragraph A.2.7).
Lh lamination height
Lmsd spacing to the nearest major structural discontinuity
Ls lamination-to-lamination spacing
Lw spacing to nearest weld joint
LOSS amount of uniform metal loss at the time of the assessment.
MAWP maximum allowable working pressure
MAWPC maximum allowable working pressure based on circumferential stress
P internal design pressure
R inside radius corrected for LOSS and FCA as applicable
s lamination dimension in the longitudinal direction
S allowable stress
tcmin average measured wall thickness of the component based on the circumferential CTP determined at the
time of the inspection.
tc corroded wall thickness, allowing for future corrosion loss
tmin minimum required wall thickness of the component (see API 579-1, Annex A, paragraph A.2).
tCmin minimum required thickness of a conical or cylindrical shell based on the stresses in the circumferential
or hoop direction (see API 579-1, Annex A, paragraph A.2).
tLmin minimum required thickness of a conical or cylindrical shell based on the stresses in the longitudinal
direction (see API 579-1, Annex A, paragraph A.2).
tmm minimum measured thickness determined at the time of the inspection
tnom nominal or furnished thickness of the component adjusted for mill undertollerance as applicable
trd uniform thickness away from the local metal loss location established by thickness measurements at the
time of the assessment.

Vessel Data
Material SA-516, Grade 70, year 1998
Allowable stress in tension 17500 psi
Design Pressure (P) 125 psig @ F
Inside Diameter (D) 120 in
Inside Radius (R) 60.063 in with metal loss and FCA applied to the inside surface
Corrosion Allowance (FCA) 0.0625 in
Weld Joint Efficiency (E) 1
Nominal Thickness (tnom) 0.500 in
Uniform thickness away from
local metal loss (trd) 0.500 in
LOSS 0.00 in

Perform a Level 2 Assesment per API 579-1, Part 13.

a)
STEP 1 – Determine if there is any surface bulging on either the inside or the outside surface of the
component at the location of the lamination. If there is surface bulging, then evaluate the lamination the
lamination as a blister using the Level 1 Assessment method in API 579-1 Part 7.
Does the inspection report indicate surface bulging on either the inside or outside surface of the
component at the location of the lamination:
Lamination 1: No
Lamination 2: No
Lamination 3: N/A
Lamination 4: N/A

(b) STEP 2 - Determine the information in paragraph 13.3.3.1

Table 1
Size, Location and Spacing for Laminations
Data required for Level 1 and Level 2 Assessment
Lamination Identification 1 2 3 4
Dimensions s (1) 4.5 in 3.0 in
Dimensions c (1) 3.25 in 6.5 in
Lamination Height Lh (1) 0.125 in 0.100 in
Edge-to-Edge Spacing to the nearest lamination Ls (2) 11.0 in 11.0 in
Minimum Measured Thickness tmin (1) 0.325 in 0.325 in
Spacing to the Nearest Weld Joint Lw (2) 10.0 in 25.5 in
Spacing to the Nearest Structural Discontinuity Lmsd (2) 42.0 in 28.0 in
Surface bulging present No No N/A N/A
Through-Wall Cracking (Yes/No) No No
Internal metal loss at lamination location 0.0 in 0.0 in
Are there two or more laminations at different depths Yes Total : 2
Are both laminations on the same plane N/A
Notes:
1. See Figure 1
2. See Figure 2
(c) STEP 3 – If there are two or more laminations on the same plane, there is no indication of through
thickness cracking, and the spacing does not satisfy Equation (13.1), then the laminations shall be
combined into a single larger lamination in the assessment. If there are two or more laminations at
different depths in the wall thickness of the component and the spacing does not satisfy Equation (13.1),
then the group of laminations shall be evaluated as equivalent HIC damage using the Level 1
Assessment method in Part 7. In applying this criterion, the spacing shall be measured parallel to the wall
thickness. Applying Equation (13.1): Ls > 2tc

2tc = 2(trd - FCA)

= 0.875 in

Ls = 11.0 in

Is Ls > 2tc YES

Equation (13.1) is satisfied

Are there two or more laminations on the same plane: YES

Are there two or more laminations at different depths: NO
Is there any indication of through wall thickness cracking: NO

(d) STEP 4 – If Equation (13.2) is satisfied, proceed to STEP 5; otherwise, evaluate the through-thickness
component of the lamination as a crack-like flaw using the Level 1 Assessment method in Part 9. In this
evaluation, the crack depth shall be equal to 2a = Lh and the crack length shall be equal to:

2c = max[s,c].

Applying Equation (13.2): Lh ≤•max[s,c]

1) Lamination 1
0.09•max[s,c] = 0.405 in
Lh = 0.125 in
0.125 ≤ 0.405 in
Equation (13.2) is satisfied for lamination 1

2) Lamination 2
0.09•max[s,c] = 0.585 in
Lh = 0.100 in
0.100 ≤ 0.585 in
Equation (13.2) is satisfied for lamination 2
(e) STEP 5 – Determine the wall thickness to be used in the assessment using Equation (13.3) or Equation
(13.4), as applicable. Applying Equation (13.3):
tc = tnom - LOSS - FCA

tc = tnom - LOSS - FCA = 0.4375 in

(f) STEP 6 – If all of the following conditions are satisfied, proceed to STEP 7; otherwise, the lamination is not
acceptable per the Level 1 Assessment procedure.

1) There is no indication of through-thickness cracking.

 Inspection report indicates no evidence of through-thickness cracking.
2) The lamination is not surface breaking in accordance with Equation (13.5):
tmm ≥ 0.10tc

i) Lamination 1
0.10 tc = 0.04375 in
tmm = 0.325 in
0.325 ≥ 0.04375 in
Equation (13.5) is satisfied for lamination 1.

ii) Lamination 2
0.10 tc = 0.04375 in
tmm = 0.325 in
0.325 ≥ 0.04375 in
Equation (13.5) is satisfied for lamination 2.

3) The distance between any edge of the lamination and the nearest weld seam satisfies Equation
(13.6):
Lw ≥ max[2tc, 1.0 in]
2tc = 0.875 in from Equation (13.1)

i) Lamination 1
Lw = 10.0 in
max[2tc, 1.0 in] = 1.0 in
10.0 ≥ 1.0 in
Equation (13.6) is satisfied for lamination 1.

ii) Lamination 2
Lw = 25.5 in
max[2tc, 1.0 in] = 1.0 in
25.5 ≥ 1.0 in
Equation (13.6) is satisfied for lamination 2.
4) The distance from any edge of the lamination to the nearest major structural discontinuity satisfies
Equation (13.7):
Lmsd ≥ 1.8 √(Dtc)
1.8 √(Dtc) = 13.04 in

i) Lamination 1
Lmsd = 42.0 in
42.0 ≥ 13.04 in
Equation (13.7) is satisfied for lamination 1.

ii) Lamination 2
Lmsd = 28.0 in
28.0 ≥ 13.04 in
Equation (13.7) is satisfied for lamination 2.

5) If the lamination is in hydrogen charging service, then the planar dimensions of the lamination
satisfy Equations (13.8) and (13.9):
s ≤ 0.6 √(Dtc)
 c ≤ 0.6 √(Dtc)

Review of process operating conditions indicates the vessel is not in hydrogen service.

(g) STEP 7 – Determine the MAWP for the component (see Annex A, paragraph A.2) using the thickness from
STEP 5. The component with the lamination is acceptable for operation at this calculated MAWP.
MAWP.
In calculating the component MAWP, P ≤ 0.385SE and tcmin ≤ 0.5R (Longitudinal Joints), and
supplimental loads are negligible, so Equation (A.10) pertains.

Lamination 1 Lamination 2
S = 17500 S= 17500 psi
E= 1 E= 1
tc = 0.4375 tc = 0.4375 in
R = 60.0625 R= 60.0625 in

Using the maximum value or R above for Lamination 1 and Lamination 2, R = 60.0625 in
𝑀𝐴𝑊𝑃𝐶=
𝑆𝐸𝑡𝑐/(𝑅+0.6𝑡𝑐)= 126.92 psig

A A

Periphery of
Lamination Lamination

Lamination Plan View

tmm

tc Lh

s or c

Section A-A
Cross Section of Lamination
 Figure 1 - Typical Lamination

Lamination 1 Lamination 2

c2
Ls

Lw
c1

s1 s2

a) Planar View of Laminations Close to a Weld Seam and to Other

Laminations

Lw s1 s2

a) Cross Sectional View of Laminations Close to a Weld Seam and

to Other Laminations

Figure 2 - Weld Joint Spacing and Multiple Laminations