Part 9: Crack-like flaws Presented by : Shahab Zangeneh

General
Part 9 in API579 utilizes for FFS Assessment of crack-like flaws in
components. These assessment procedures are based on the Failure
Assessment Diagram FAD method.

Crack-like flaws are planar flaws that are predominantly

characterized by a length and depth, with a sharp root radius. Crack-
like flaws may either be surface breaking, embedded, or through-
wall. Examples of crack-like flaws include planar cracks, lack of
fusion and lack of penetration in welds, sharp groove-like localized
corrosion, and branch type cracks associated with environmental
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Part 9: Crack-like flaws Presented by : Shahab Zangeneh

Applicability and Limitations of the FFS Assessment based on Part 9

1. The original design criteria were in accordance with a recognized code or standard.
2. The material is considered to have sufficient toughness.
3. Dynamic loading effects are not significant e.g., earthquake, impact, water hammer, etc. .
4. The crack-like flaw is subject to loading conditions and/or an environment that will not result in crack growth.
5. The following limiting conditions are satisfied for a Level 1 Assessment:

 The component is a flat plate, cylinder, or sphere.

 Cylinders and spheres are limited to geometries with 𝑅/𝑡 5 where R is the inside radius and t is the current thickness of
the component.
 The wall thickness of the component at the location of the flaw is less than 38 mm 1.5 inches .
 The crack-like flaw geometry can be of the surface or through-thickness type with The maximum permitted crack length is
200 mm 8 inches .
 For cylindrical and spherical shell components, the crack-like flaw is oriented in the axial or circumferential direction.
 Crack-like flaw is located at a distance greater than or equal to 1.8√𝐷t from any major structural discontinuity.
 The loading on the component is from pressure that produces only a membrane stress field within the design limits of the
original construction code.
 The material is carbon steel P1, Group 1 or 2 with an allowable stress that does not exceed 172 MPa 25 ksi .
 The specified minimum yield strength for the base material is less than or equal to 276 MPa 40 ksi , the specified minimum
tensile strength for the base material is less than or equal to 483 MPa 70 ksi .
 The fracture toughness is greater than or equal to the lower bound KIC value.
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Part 9: Crack-like flaws Presented by : Shahab Zangeneh

Required Data/Measurements for an FFS Assessment – Loads and Stresses

The stress distribution at the cracked region of the component should be determined for all relevant loads based on the
planned future operating conditions.

Required Data/Measurements for an FFS Assessment – Material Properties

The yield and tensile strength of the material are required in the FFS Assessment to determine the effects of plasticity on
the crack driving force, estimate the residual stress, and evaluate the fracture toughness using correlations with other
material toughness parameters.

Required Data/Measurements for an FFS Assessment – Flaw Characterization

The part through-wall depth of a flaw can be considerably more difficult to estimate than the length. Therefore, If no
information is available about the depth of a flaw, a conservative assumption is that the flaw penetrates the wall, i.e., 𝑎
𝑡 for a surface flaw.

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Part 9: Crack-like flaws Presented by : Shahab Zangeneh

Assessment Techniques and Acceptance Criteria

Level 1 assessment
This level is a screening criteria limited to crack-like flaws in pressurized cylinders, spheres, or flat plates away from all
structural discontinuities.

STEP 1- Determine the load cases and temperatures the CET see Part 3 should be considered to be used in the
assessment based on operating and design conditions.
STEP 2- Determine the length, 2𝑐, and depth, 𝑎, of the crack-like flaw from inspection data.
STEP 3- Determine the Screening Criteria for the assessment based on the component geometry and crack-like flaw
orientation with respect to the weld joint.
 Two sets of screening curves, 1/4-t and 1-t crack depths, are provided for three conditions; base metal, weld metal
that has been subject to PWHT, and weld metal that has not been subject to PWHT.
 If the depth of the flaw can be accurately determined using qualified NDE procedures, then the 1/4-t flaw curve can
be used in the assessment based on the criteria; otherwise, the 1-t flaw curve should be used.

 For t 25 𝑚𝑚 1 in :

 For 25 𝑚𝑚 1 in 𝑡 38 𝑚𝑚 1.5 in :

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Part 9: Crack-like flaws Presented by : Shahab Zangeneh

Assessment Techniques and Acceptance Criteria

Level 1 assessment
STEP 5- Determine the reference temperature. Based on the material specification determine the Material Temperature
Exemption Curve using Part 3, Table 3.2 and the Specified Minimum Yield Strength SMYS at ambient temperature
based on the original construction code.
STEP 6- Determine the maximum permissible crack-like flaw length. Enter the assessment Figure established in STEP 3
with the assessment temperature and reference temperature determined in STEPs 1 and 5, respectively, to determine
the maximum length of the flaw 2𝑐 using the applicable screening curve.

STEP 7- Evaluate Results – if the permissible flaw size determined in STEP 6 is greater than or equal to the length of the
crack-like flaw determined in STEP 2, then the component is acceptable for future operation.
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Part 9: Crack-like flaws Presented by : Shahab Zangeneh

For example, for an A516 grade 70

material, the exemption curve from Part
3, Table 3.2 is B. The SMYS for this
material is 262 MPa 38 Ksi . The
material is carbon steel; therefore, is
based on the 20 Joule or 15 ft-lb
transition temperature. Based on these
data, the reference temperature from
Table 9.2 is 𝑇𝑟ef 10.3℃ 51.1℉ .