Cumulative Damage

Copyright Paulin Research Group © 2019. All Rights Reserved.

 Cumulative Damage

Table of contents

Cumulative Damage Introduction and Theory ........................................................ 4

Cyclic and Severely Cyclic Piping Systems and Theory ........................................ 4
Recommendations for Running ...................................................................... 10
Getting Started ................................................................................................. 13
Loading a model .......................................................................................... 14
Required inputs ............................................................................................ 15
Analyzing the model ..................................................................................... 16
Understanding the output .............................................................................. 16
Text Reports ............................................................................................ 17
Summary ............................................................................................ 18
Stress Cycle Report ............................................................................... 18
Detailed Report .................................................................................... 19
Stress Cycle Report (Sorted) .................................................................. 19
Detailed Report (Sorted Stress) .............................................................. 19
Stress Report (Inspection Points) ........................................................... 20
Detailed Report (Inspection Points) ........................................................ 20
Detailed Report LTA (Inspection Points) .................................................. 21
2D Charts ................................................................................................ 23
Cumulative Damage Window ............................................................................. 23
Toolbar ....................................................................................................... 24
Grid Columns .............................................................................................. 26
Grid Options .................................................................................................... 26
Inspection Points .............................................................................................. 27
Cumulative Damage Files .................................................................................. 27
Fundamental Properties .................................................................................... 29
Fatigue Damage Equation .............................................................................. 30
Use fm = 1.2 ............................................................................................... 31
Do NOT Consume Cycles when Counted ......................................................... 32
Fluid Category ............................................................................................. 32
SIF Origin ................................................................................................... 33
Pressure Test ............................................................................................... 33
Cycle Service Category .................................................................................. 33
Environmental Effect ..................................................................................... 33
Environmental Option ............................................................................... 33
Fen - Environmental Loss Factor ................................................................ 34
Local Thermal Analysis ................................................................................. 34
Maximum thermal ROC ............................................................................. 34
Maximum stratified temperature difference .................................................. 34
Cycle Multipliers ........................................................................................... 35
Cycle Multiplier ........................................................................................ 35
Cumulative Damage Files Cycle Multiplier .................................................... 35
Stress tolerance to print ................................................................................ 35
Line operates with gas at pressure .................................................................. 35
Avoid leak at all cost ..................................................................................... 35
Inspection ................................................................................................... 36
Inspection Points Data .............................................................................. 36
FFS Material Properties .......................................................................... 38

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Optional .......................................................................................... 38
Probability of failure ..................................................................... 40
Primary load certainty ................................................................... 41
Nominal thickness at flaw .............................................................. 42
Material's Nil Ductility .................................................................... 43
Local radius of curvature ............................................................... 44
Number of operating cycles ........................................................... 45
Ignore partial safety factors ........................................................... 46
Flaw is exposed to a marine environment ........................................ 47
Flaw region has been post weld heat treated ................................... 48
Secondary loads are applied dynamically ......................................... 49
Advanced ........................................................................................ 49
Define known material properties ................................................... 50
Facture toughness values are known ............................................... 51
Use ciritical J value to calculate toughness ....................................... 52
Use CTOD value to calculate toughness .......................................... 53
Use Charpy impacts to calculate toughness ...................................... 54
Local Thin Area (LTA) Properties ........................................................... 54
Local point-to-load location ............................................................... 54
Local thin area ................................................................................. 55
Average thickness of thinned zone ................................................. 56
Longitudinal length of thinned zone ................................................ 57
Circumferential extent of thinned zone ............................................ 58
Results ........................................................................................ 59
Inspect per Fluid Service ........................................................................... 59
Inspect per Severe Cyclic Service ................................................................ 60
Weld root passes generally NOT inspected .................................................. 60
Weld root passes 100% visually inspected ................................................... 60
All welds 100% visually inspected .............................................................. 60
All welds 100% radiographed .................................................................... 60
Current State ............................................................................................... 60
Total service life ....................................................................................... 61
Current time in operation .......................................................................... 61
Time before next shutdown ....................................................................... 61
Occasional Load Determination ...................................................................... 61
Occasional loads can be due to waterhammer .............................................. 62
Occasional loads can be due to earthquake .................................................. 62
Occasional loads can be due to blast ........................................................... 62
Line is subject to pulsating pressure loads ................................................... 62

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Cumulative Damage Introduction and Theory

The Cumulative Damage program performs fatigue analysis and cycle counting for piping systems that where built
using CAESAR II or PCLGold. The rules followed for cycle counting are based the ASME B31 codes.

The topics in described in this section are important in understanding why this product must be used on piping
lines that cycle.

· Cyclic and Severely Cyclic Piping Systems and Theory

· Recommendations for Running

Non-Cyclic Service Limits

Stress Eqn. Used fm N
1a 1 4800
1b 1 1055
1a 1.2 2800
1b 1.2 600

Severely-Cyclic Service Limits

Stress Eqn. Used N
1a 400000
1b 9300

Cyclic and Severely Cyclic Piping Systems and Theory

The Cumulative Damage Tool processes piping models (CAESAR II, PCLGold and MiM based) per ASME B31.3
equation Eqs. 1a and 1b., ASME VIII-2 Part 5, and API 579/FFS-1, and performs the following functions:
1) Evaluates cyclic and non-cyclic service per safety factor tables shown below. (Non-cyclic service behavior
provides Code safety factors greater than typical Code SIF errors returning piping systems to the intended
safety factor against thru wall cracking at the end of service life.)
2) Performs fitness for service of piping components

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3) Evalutes bar supports and local thin areas at bar supports

4) Allows the user to enter crack growth from measurements. The growth history will be compared to expected
growth history and the user can determine if cracking is principally due to stress or some other mechanism.
5) Includes the effect of local rate of temperature change in a manner similar to ASME III Subsection NB.
6) Recommends inspection intervals for cyclic systems.
7) Predicts failure life of cracks or new pipe systems.
8) Includes the effect of corrosion on allowable stress using FEN method
9) Performs accurate cumulative damage calculation using ASME VIII Part 5 Annex 5A Min-Max cycle counting
on a node-by-node basis.
10) Computes allowables and life based on Hinnant and Markl fatigue allowable curves.
11) Interacts with BOSB31 to include fatigue damage due to various fluid loadings

The cumulative damage tool should be used whenever:

1) The cycles are outside the table limits given below
2) Fatigue should be considered in the piping system analysis
3) Known fluid loading produces high cycle forces on the piping system
4) Cracks or local thin areas are present in the piping system
5) The user must evaluate the effect of corrosion on fatigue life.
6) Multiple (more than 1) significant thermal and/or pressure cycle is present
7) Systems heat up or cool down faster than 10degF per min.
8) Through-wall cracks of the piping system are considered highly consequential in a risk analysis of the
piping system.

The cycles from the operating and sustained cases are counted and consumed together to perform an accurate
calculation of the damage performed by each cycle.

The Cumulative Damage Tool performs a MIN/MAX cycle counting method, where the highest range is consumed
first and all others are consumed subsequently and taken out as a ratio of the cycle.

Depending on the equation used to perform cycle counting, the number of cycles below should be used to
determine whether a system is non-cyclic, cyclic or severely cyclic system. The ASME B31.3 code does not have a
definition for severely cyclic in the post 2010 versions. The definition of severly cyclic is left to the owner. The
tables below are offered as recommendations since they establish the following breakpoints:

1) Non-cyclic – approximate safety factor on stress-to-mean-failure is 4 or greater

2) Cyclic – approximate safety factor on stress-to-mean failure is between 4 and 2.
3) Severely cyclic – approximate safety on stress-to-mean failure is less than 2.

Most non-conservative stress intensification factor errors are around 2, (although when the t/T ratio is less than
1 non-conservative stress intensification factors can be greater than 2 however.) Setting the safety factor on life of
4 allows for most non-conservatveessresse nsens icatoneoacsorsessasesaveeveene nesseeho ees nceecarMarseor o naa
work was used. Note that B31J-2017 Table 1-1 corrects the known non-conservative (and overly-conservative)
stress intensification factors. All B31.1 and B31.3 Code Appendix D SIF equations through 2018 do not have
nonconservative SIFs corrected although do refer to B31J-2017

Systems that cycle within the Non-Cyclic Service Limits below should not be susceptible fo fatigue related issues.
This is believed to be the reason why the piping industry has been able to function using non-conservative SIFs for
more than half a century. Most piping systems do not cycle, and so actual safety factors are much higher than
intended safety factors. Unfortunately this has resulted in the manufacture of some fittings that do not conform
with the geometries and thickness distributions of those originally tested by Markl and Kahn. The non-cyclic
service limit table suggests that designers and operators only need to be concerned with this problem when the
consequence of a thru-wall leak is high, and when the number of cycles are greater than those in the non-cyclic
service limit table. (See PVP2019-94074 “Implementing B31J-2017 SIF and Flexibility Factor Changes for B31
Piping Systems”, Becht, Carpenter, Paulin.)

Non-Cyclic Service Limits

Stress Eqn. Used fm N

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1a 1 4800
1b 1 1055
1a 1.2 2800
1b 1.2 600

Severely-Cyclic Service Limits

Stress Eqn. Used N
1a 400000
1b 9300

If there is more than one significant cycle, then the number of significant cycles (N) used to determine the limits
identified in the table above can be found by conservatively summing the number of significant cycles or by using
the following equations from PVP2019-94074:

An intended use of the non-cyclic and severely cyclic tables is to:

1)Motivate the pipe stress analyst to accurately estimate the number of cycles for a piping system that is being
evaluated, and
2)To use B31.3 Eq.(1a) for the allowable stress with a limit on the value of fm of 1.0.

The major use of the cumulative damage tool is to provide a counting mechanism for pipe stress analysts to
properly sum the fatigue damage from a given number of operating cases. The table below for example shows the
number of range cases for each operating state that must be evaluated. (Ref. B31.3 Example S303.)

For example, there will be 21 stress ranges to be evaluated if there are 6 operating states. Defining the operating
states is generally easy, and establishing the range case permutations is easy to do, but counting the number of
cycles for each range is difficult because the counting must be done on a node-by-node basis.
In a particular system with 3 thermal cycles, the cycles at one node for one week are calculated as shown below:

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Simplified Stresses for Each of 3 Operating Cases for One Week at Node 1

If the system is designed to operate for 40 years, then the total number of weeks is 52 x 40 = 2080 weeks. The table
above shows that for 3 operating cases (a., b., and c.) there will be 6 ranges. The six stress ranges are shown
above, i.e. 8, 10, 20, 28, 30, 38. The users dilema is to decide which ranges go with which cycles. There are two
occurances of stress a., 4 occurrances of stress b., and one occurance of stress c. each week.

To count the cycles for this node following the guidelines in the min-max cycle counting method in ASME VIII-2
Part 5 Annex 5.B the user would combine the stress ranges in the following way:

Highest range available to be counted is 38. It occurs once per week between operating case b. and c. This range
will consume all the occurances of case c., and one of the occurances of case b.

The next highest range that has not already been consumed is 28. There will be 3 occasions where the stress b.
range appears per week. This consumes all of the stress occurances of b. and c., and so the stress a. case at 20
can occur two times. The table below shows the sum of the ranges:

Stress Total
# Count Cy per wk
Range Cycles
1 b. to c. 1 38 2080
2 b. to 0. 3 28 6240
3 a. to 0. 2 20 4160

The stresses at another node iin the same piping system are shown in the chart below. In multibranch piping
systems where one branch can be hot while another is cold, the changes in stress from node to node do not vary
monotonically. The highest forces and moments can change both magnitude and orientation.

Simplified Stresses for Each of 3 Operating Cases for One Week at Node 2

The highest range available to be counted for Node 2 is 41. It occurs once per week between operating case a. and
c. This range will consume all the occurances of case c., and one of the occurances of case a.

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The next highest range that has not already been consumed is 27. There is only one range of 27 between a. and b.
since one of the a. weekly cycles was consumed forming the stress range of 41. This consumes all of the stress
occurances of a. and c., and so the stress case b. can occur three times. The table below shows the sum of these
ranges:

Stress Total
# Count Cy per wk
Range Cycles
1 a. to c. 1 38 2080
2 a. to b. 1 28 2080
3 b. to 0. 3 20 6240

Putting the two tables side-by side one can see how in a relatively simple system can have variations in stress
range combinations from node-to-node.

Node 1 Node 2

For a single node in a system with 6 operating cases there will be 21 different POSSIBLE combinations of stress
ranges. The 21 different combinations and cycle counts for a single node is shown below. Several observations
can be made from this table.

1) The output is for the beam element fom the node 10.0 to 15.4
2) The stresses for each node are sorted from highest to lowest.
3) The range that produces the highest stress at node 10.0 is from case 7 to case 16.
4) The range that produces the highest stress at 15.4 is from case 10 to 13.
5) For the node 10.0 case 16 shows up three times in the first four cases. (Case 16 happens to appear as case “i”
for these cases. The cycles for case 16 – “Case i” 200. So we can tell right away that during cycle counting the
case 16 will only appear one time because it will be consumed with the first use with case 7. (Case 7 (which is “i”
in the first row in the table below combined with case 16) appears 1500 times, but only 200 of those can be used
with case 16. (Because 16 only appears 200 times.)

This cycle counting long is spelled out in detail in ASME VIII-2 Part 5 Annex 5.B. Below the table is the actual
counted ranges that will be used in B31.3 Eq. 1d for the cumulative damage calculation.

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Cycle Counts for the all “possible”eranges above.

In the cycle range table above, the highest stress (42.4 ksi) appears with the range from 7 to 16, and as described
above, this range can only appear 200 times because the stress case 16 only appears 200 times. Note that case 7
appears 1300 times in the next case, with case 4. Case 7 only has 1300 cases left after it has used 200 already
with the first combination.

The applicable equations from B31.3 are shown below:

Referring to the above table, the maximum stress is 42.4 ksi, and so NE = 200 in Eq. 1d.
The Ni values for Eq.1d are 1300, 700, 100, 50 and 350, for this particular problem. The corresponding ri values to
be used in Eq. 1d are 35.6/42.4, 28.3/42.4, 24.3/42.4, 22.7/42.4 and 21.2/42.4. These are shown for clarity in the

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table below:

Markl Hinnant
Ni ri ri Cycles Cycles
(exp=5) (exp=3)
1 1300 35.6/42.4 0.8396 542 769
2 700 28.3/42.4 0.6674 93 208
3 100 24.3/42.4 0.5731 6 18
4 50 22.7/42.4 0.5353 2 7
5 350 21.2/42.4 0.5000 11 44
Total = 654 1048

The Markl exponent used in the Code current 2018 version is clearly non-conservative and does not follow the
slopes of other welded fatigue curves in ASME VIII-2 or around the world. For this reason the Hinnant slope of 3
is recommended as a more reasonable exponent when performing cumulative damage. The cumulative damage
processor calculates both values and shows them to the user.

For the calculation shown here: referring to Eq. (1d)

N = 200 + 654 = 854 (Markl)

N = 200 + 1048 = 1248 (Hinnant)

Using Eq. 1c:

f = 6.0 (854)-0.2 = 1.55 (Markl)

f = 20.6 (1248)-0.335 = 1.89. (Hinnant)

The limit for “f” is 1.2 for ferrous materials, but to use the first row in the Non-cycle table, f=1.0.

If Sc=Sh= 20ksi, and SL=0ksi, then Eq. 1a and 1b are:

Sc, Sh f f
Eq. Term Value Stress Ratio
(ksi) (Markl) (Hinnant)
1a 20 1.25Sc + 0.25Sh 30 1.0 1.0 42.5 1.42
1b 20 1.25(Sc+Sh) 50 1.0 1.0 42.5 0.85

The Markl and Hinnant f – factors for the Code calculation are the same because the limit (fm) is 1.0 or 1.2 for
ferritic materials - or as the user determines.

Note that in this example, Eq. 1a shows the node to be overstressed by 42% while Eq. 1b shows the node to be
under the allowable by 15%.

These calculations are all performed automatically in the cumulative damage processor. Additionally the
cumulative damage processor can switch back and forth between a variety of options to determine the impact
each has on the calculation.

Each of these options and and a variety of others are explained in detail in the body of this manual.

Recommendations for Running

1) Read in the CAESAR or PCL model
2) Assign the number of times the particular stress state might appear

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3) Press the “Perform Cumuative Damage” button .

4) Make sure that all the default curves shown are less than unity (see the plot below):

Note that both the Markl (B31 Current) and Hinnant allowables exceed 1.0 and so there are some overstressed

points in the model. In this case, the user should check the of the calculation to see what
code stress equation is being used and what maximum value of fm is allowed. The default value which produced
the above plots is shown below:

These are the most conservative approaches. Equation 1b is less conservative, but still in accordance with the
Code, and the maximum value of fm can be 1.2 (instead of 1.0). As per B31.3:

When the Fatigue Damage Eq. is changed to 1b and the use fm=1.2 checkbox is checked:

When the button is pressed again, the default plot now shows all curves
are less than unity (below).

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There are also an extensive number of tabular reports. An example report summary is shown below:

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Getting Started

The cumulative damage tool can be found in the FEPipe suite and Advanced FEATools main windows as shown
below.

· Loading a model
· Required inputs
· Analyzing the model
· Understanding the output

FEPipe suite:

FEATools:

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Loading a model
When the cumulative damage tool is opened, the following window will appear with the recent files loaded. The
first time the tool is opened, the window will be empty, pressing the Browse... button will allow the user to select a
piping model from the local or network drive.

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The Continue button will open the tool without loading a model. The OPEN SELECTED will open the selected model
from the list above. Double-clicking on the row will perform the same operation ad OPEN SELECTED.

If Continue is pressed, then the model can be loaded at a later time using the Open button found in the main
toolbar.

Required inputs
Once the model is loaded, some inputs need to be added. The image below shows a loaded model that has been
translated for better flexibilities using the CAESAR II FEA Translator. The only required inputs is to select the
Expansion cases that are to be analyzed, but the number of cycles must be added to the operating cases that form
part of the expansion cases. The cycles occur on operating cases, not on expansion cases, since the range is what
is important from the operating and sustained cases.

In the example below, expansion cases 5 and 6 will be analyzed using 24960 cycles for the operating case in load
case 1.

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More information about what each column represents will be explained in later sections of this manual.

Analyzing the model

Pressing the Perform Cumulative Damage button will perform the cycle counting calculation and output reports
and plots.

Default options will be used unless the options in the Fundamental Properties window are changed. The tool will
assume conservative defaults and therefore no changes are required. It is recommended that the user looks and
understands the default options. These will be explained in later sections.

Understanding the output

Once the analysis has been performed, two windows will open. The first window is the text reports while the
second is the graphical output. The graphical output is in the form of 2D charts. Charts make is easier to inspect
the output for all nodes in the model.

· Text Reports
· 2D Charts

Text Reports

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Charts

Text Reports
The text reports window contains multiple reports for different topics. Below is a list of the text files available.

· Summary
· Stress Cycle Report
· Detailed Report
· Stress Cycle Report (Sorted)
· Detailed Report (Sorted Stress)
· Stress Report (Inspection Points)
· Detailed Report (Inspection Points)

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· Detailed Report LTA (Inspection Points)

Note that any of the reports can be exported to Microsoft Word in a Rich Text Format (*.rtf).

Summary
The Summary report gives an overview of the entire system.

The section of the report shown below shows the highest stress fraction found and the node it was found on. The
stress fraction is shown for 3 different codes, where the allowables might differ. Any value greater or equal to 1.0
means that there is an overstress due to fatigue and that an inspection is important at the location of the given
node in the piping system.

The section of the report compares the life fraction and stress fraction based on mean failure.

The section below shows how many nodes are outside of the limits, meaning that this is a cyclic piping system.
Table A below shows the limits of non-cyclic service based on equations 1a and 1b from ASME B31.3.

Stress Cycle Report

The Stress Cycle Report shows the stresses for every element in the model as they were coded in the piping model.
The expansion stress and the allowable stress ratios are shown for 2 difference curves, Markl and Hinnant.

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Markl SA = CN^-0.2; C=245,000 psi

Hinnant SA = CN^-0.335; C=797500 psi

Detailed Report
This is a detailed report of how stresses are calculated and the load case information for each range. Every
element stress is shown in the table, the life fraction and whether inspection is required for this particular
element. This report can be long depending on the number of elements in the piping model.

The order of the report is as it was entered in the piping model.

Every load case that is analyzed in shown in the table together with the number of cycles for each load case. The
life fractions for mean, and 2 standard deviations are shown for Markl and Hinnant equations.

Stress Cycle Report (Sorted)

This report is very similar to Stress Cycle Report, but it is sorted from highest to lowest stresses.

Detailed Report (Sorted Stress)

This report is very similar to the Detailed Report, but stresses are sorted from highest to lowest.

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Stress Report (Inspection Points)

Inspection points are locations where Fitness for Service is to analyzed for a specific node.A more detailed
explanation on the inspection points is found in the Fundamental Properties section.

This report contains the same output as Stress Cycle Report, but only for the node defined for an inspection point.
Essentially, this report filters the Stress Cycle Report.

Detailed Report (Inspection Points)

This report contains information regarding fitness for service. The first part of the report is a filter of the Detailed
Report for the given inspection node. In addition, it will show the % chance of finding an crack indication using
different methods such as Liquid Penetrant, Fluorescent Penetrant and Phased Array.

The second part of the report for the given inspection node is input and equivalent depth calculations. In the
example below, the equivalent depth will be different if the entered depth x ratio (equation shown below) if the
length is smaller than 4x the thickness.

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Detailed Report LTA (Inspection Points)

When a local thin area (LTA) has been defined through Inspection Points, this report will show the results for
fitness for service for the flaw.

The first part of the report is the input echo of the local thin area. The Local Point-Line load is when a bar, or beam
is used to support the pipe. This is common on off-shore piping, and local thin areas appear at the supports due
to humidity and environmental circumstances.

In this case, there is a local thin area together with a local point or line support at a given node. The extent of the
local thin area can be specified along the circumferential direction and the longitudinal direction.

The second part of the report shows calculations for the local thin area. Note describe the results. Note that the
the Adjusted stress is the stress using the section modulus based on the corroded thickness. Therefore, the stress
will be higher at this location.

Buckling calculations are performed if the length of the local thin area is greater than SQRT(RT), where R is the
midsurface radius and T is the corroded thickness. In these cases, local buckling might become an issue.
References for buckling calculations are found in the noted below. The buckling allowable is compared to the
adjusted stress at the section.

Note that the results are given for every load case in the model.

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The third part of the report shows pressure calculations for local thin areas. Piping programs do not account for
pressure stresses for fitness for service. The Sp stress based on the local thin area thickness is calculated and
compared to 2/3 Sy. This is a reasonable approach to predict whether a straight pipe or elbow will fail under
pressure for a reduced thickness location.

The last part of the report for the given flaw shows the point support calculations. These are calculatedf using the
corroded thickness and section modulus. The allowable force is calculated based on Pipe Stress Engineering by
Peng and Peng, calculating the maximum allowable normal force acting on the pipe. This is compared to the
actual normal force from the piping program.

A membrane and bending stresses are also compute based on the forces acting at the node. The allowable stress
in the case is the yield strength.

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2D Charts
The 2D charts show the same results as the text reports, but in 2D form. There is additional information also
shown for diameters and D/T ratios.

Cumulative Damage Window

The main Cumulative Damage tool window is shown below. There are three aspects of the window that this
manual will explain in more details. The toolbar at the top, which shows different icons, the grid section of the
window that shows the cycles, load cases and more columns, and the buttons shown at the button of the window
(these will be explained in separate topics).

· Toolbar
· Grid Columns

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Toolbar
The toolbar allows access to multiple features within the software.

To load a recent file or a new file, the yellow folder can be pressed to load a file from the local machine or network
drive.

Pressing on the black arrow on the right will show the recent files. Pressing on a recent file name will load the file.

The blue disk button will save the model into a <jobname>.MiM.PrgPipe file. This file should be sent to via email
together with the piping file in order to ensure that the cycles, flaws, etc. are preserved.

As of the current version, only 2 piping program input files can be loaded. PCL Gold and CAESAR II. Depending on
the type of file loaded, one of the two icons will be enabled. Pressing on the button, the piping program will load
with the loaded piping file.

BOSB31 is a program part of the FEPipe suite and the Advanced FEATools suite. This is a program to calculated
dynamic stresses based on different types of fluid loads (e.g. water hammer, two-phase flow) within a piping

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system. This icon is included in this program because loads from fluids can cause fatigue damage on the piping
system. Many of the fluid loads are cyclic in nature and can therefore contribute to the overal fatigue damage in
the system.

The output of BOSB31 can be included in this program. More on this in the Cumulative Damage File section of this
manual.

The piping model can be plotted for a quick review of where the nodes are located, diameters, thickness and other
properties of the model.

Clicking this button will open a separate window with the 3D geometry as shown below.

Units can be changed with the ruler icond shown below. The default is in US Customary units. The units can be
kept the same as the input file's units.

The grid options can be opened through the icon shown below. More information on this window in the Grid
Options section of this manual.

The icons below will open the text reports and 2D chart output respectively. More on this can be found in the
Understanding the Output section of this manual.

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The icon below opens this help manual or the PDF format

Grid Columns
Each column in the grid shows different information. The way fatigue damage calculations are made depends on
the user entries in the columns.

Load Case Description and Type - The first 3 columns show read only information. These load cases are imported
from the output of the pipe stress program. If these load cases need to be changed, the piping program must be
opened, modified and re-analyzed. Once that is completed, the model must be loaded once again into this
program.
The load case type is shown in the column. This is important for fatigue damage, since the expansion cases are
the ones that cause fatigue damage.

Include as Stress Range in Damage Summation - This is an important column. The expansion cases are selected by
default, since these are the cases that cause fatigue damage. The user should select all the expansion cases that
are to be included when counting cycles for a specific load case. Note that the sustained and operating cases are
not selected.

Number of Occurrances - This column shows the cycles for the operating and sustained cases. Note that this
differs from what is commonly entered in a pipe stress program, where the cycles are entered for the expansion
case. The reason cycles should be entered in the operating and sustained cases is because in this way, the
program can see the combination of load cases in the expansion case and correctly follow a load history. Cycles
used in case 5 for example, should not be used in case 6, since these should already be consumed in the life.

Companion Number - This is an optional column. The companion number signals the program that two load cases
are to be treated as the same. To link two different load cases, the same number can be entered in both rows. This
tells the software that these two (or more) load cases are to be treated the same. What the software will do is to
consume the cycles from the one with less number of cycles and then remove this amount from the next case with
the same companion number. In this way, the same cycle is not counted twice or more times.

Stress Factor - This is an optional column. The stress factor will multiply the stress (SE) before calculations.
Default is 1.0 if blank.

SL Case - This is an optional column. The SL case can be given where SL should be used in the computation of the
allowable stress. If left blank, the software will attempt to find the correct load case for SL.

User Description - User defined notes for the given load case can be entered here.

Grid Options

The grid options allow for some manipulation of the grid.

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Allow Occurrances for EXP and FAT Cases - By default, cycles (or occurrances) cannot be entered for the expansion
and fatigue cases. The cycles for each of these is based on the cycles it references. But, if desired, cycles can be
entered in this row by selecting the box.

Allow Modifications to MAX/MIN load cases - By default, the load case types defined as MIN and MAX cases,
where multiple cases are compared to show the maximum, do not allow modifications of cycles/occurrances.
Check this box to make changes to the cycles for these load cases, although this is not recommended.

Clear ALL User Descriptions - The descriptions can be cleared by selecting this radio button and pressing Apply.
This will clear all descriptions for all load cases regardless of whether there are occurrances entered.

Clear ALL User Descriptions with No Occurrances - The descriptions for all load cases that have no cycles entered
will be cleared by selecting this radio button and pressing the Apply button.

Inspection Points

This button opens the Inspection Points window that is found in the Fundamental Properties window. See here
detailed explanation of Inspection Point calculations for Fitness for Service.

Cumulative Damage Files

The Cumulative Damage files allows for the import of different program's stress results. For example, BOSB31
create a *.CUMULATIVE_COUNT file that can be loaded into this program. Once the file is loaded the stress results
and cycles will be included in the damage calculation. This is treated as a separate load case, where the Load
Case Description can be modified.

BOSB31 creates this file based on the fluid load conditions in the piping system. It is important, in certain cases,
to include the stresses from a fluid dynamic load into the damage calculation. Some fluid loads are cyclic in
nature and will contribute to the total damage. BOSB31 calculates the stresses at a nodal basis in the frequency
domain, for mechanical and acoustic modes.

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Use Cumulative Dqamage Files - This box must be checked for the software to include any external stresses.

The Plus button above adds a new tab for a separate file.
The Minus button will remove the file shown.

The icons shown below will add or remove a row from the current grid. The user can manually enter stresses at a
given node if needed.

The refresh button can be pressed when a new BOSB31 analysis has been performed with different fluid loadings
and the data needs to be refreshed.

The entries below are required to include a file in the damage calculation. The file file was obtained from the
current machine after a BOSB31 analysis. The "..." button on the right can be pressed to find the file in the current
system. Note that the files in the same working directory will be automatically loaded into the program, but not
used as a default.

The Load Case Description will be the separate load case used for the fluid loads. This name can be changed and
the 2D chart for the load case will be shown in the 2D Charts output.

The default number of cycles will be 100 if not entered.

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Fundamental Properties

The Fundamental Properties window is where most of the default settings are stored. Any of the defaults can be
changed in this window. Fitness for Service flaws for cracks and local thin areas can be entered in this window as
well.

· Fatigue Damage Equation

· Use fm = 1.2
· Do NOT Consume Cycles when Counted
· Fluid Category
· SIF Origin
· Pressure Test
· Cyclic Service Category
· Environmental Effect
· Local Thermal Analysis
· Cycle Multipliers
· Stress tolerance to print
· Line operates with gas at pressure
· Avoid leak at all cost
· Inspection
· Current State
· Occasional Load Determination

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Fatigue Damage Equation

The fatigue damage equation defaults to 1a.

The equations from 2016 ASME B31.3 are shown below. Note that SL may be considered to be zero by selecting the
3rd option in the dropdown menu item.

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The equations shown above are relevant in the calculation of allowable stress (Sa), where the "fm" factor is
calculated using equation 1c. Depending on the equation selected in this dropdown, the non-cyclic, cyclic and
severely-cyclic limits are shown below.

Non-Cyclic Service Limits

Stress Eqn. Used fm N

1a 1 4800
1b 1 1055
1a 1.2 2800
1b 1.2 600

Severely-Cyclic Service Limits

Stress Eqn. Used N
1a 400000
1b 9300

Use fm = 1.2
The default is to use fm=1.0. Select this box to use fm=1.2, making the solution more conservative.

The fm value will affect the non-cyclic, and cyclic service limits as shown in the table below. This fm value in
combination with the equation used, will determine the cyclic service limits.

Non-Cyclic Service Limits

Stress Eqn. Used fm N

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1a 1 4800
1b 1 1055
1a 1.2 2800
1b 1.2 600

Severely-Cyclic Service Limits

Stress Eqn. Used N
1a 400000
1b 9300

Do NOT Consume Cycles when Counted

The program uses the MIN/MAX way of counting cycles. The way cycles are counted is by obtaining the maximum
range between two cycles, essentially the maximum and minimum stress. This largest stress range becomes the
basis for any other cycle. Once the largest cycle is obtained, it is counted as 1 cycle and removed from the list of
cycles. The next largest is a ratio of the largest cycle and removed from the list. These cycles are consumed and
cannot be used again in another load case.

If the box shown above is checked. The same cycle can be used in different load cases, i.e. when the load case
definitions do not follow a specific load history.

The ASME code, equation 1d, counts cycle based on the A.R.C Markl equation, using an exponent of -0.2 (or 5). The
program counts cycles in two different ways, i.e. using two different exponents. The Hinnant curve with equation
in the format of S=CN^-0.335 can also be used to count cycles. The exponent in equation 1d then is changed from 5
(1/0.2) to 3 (1/0.335).

Fluid Category
Select the fluid category for the piping system being analyzed.

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Category M and Hazardous service will create a Category III service where it is very dangerous if there is a leak in
the pioping system. When a hazardous chemical is in service, the lower bound of the number of cycles to failure
will be reduced for a more conservative assumption of cycles to failure.

SIF Origin
The SIF origin tells the software how the SIF's are developed in the system. As of this version, this option is not
used.

Pressure Test
This option is not currently used. This option tells the software whether the piping system was hydrotested or
pneumatic tested.

Cycle Service Category

The Cyclic Service Category will create a factor to reduce or increase the number of years when the system must
be inspected. For severe cyclic service, the inspection on the piping system must be performed much sooner that a
normal cyclic service piping system.

Environmental Effect
Environmental effects can have an effect on fatigue damage in a piping system.

· Environmental Option
· Fen - Environmental Loss Factor

Environmental Option
The environmental option below will use the Fen value if options 3 or 4 are selected. The Fen value will have an
effect on the life predicted for the piping sytem.

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Fen - Environmental Loss Factor

If the Environmental Option is set to Use Fen Value or Use PRG Correlation, the value in this box will be used to
predict the life of the piping system.

In essence, equation 1d from the piping code will include a Fen in the summation part of the equation below. If the
box is left blank, a Fen value of 1.0 will be assumed.

Local Thermal Analysis

The thermal rate of change and stratified temperature difference may cause an additional stress in the system.

· Maximum thermal ROC

· Maximum stratified temperature difference

Maximum thermal ROC

A large rate of change in temperature will cause an additional stress in the piping system. Enter the temperature
change per minute in order for the software to calculate the additional stress to the expansion load cases where a
temperature is cycling.

Maximum stratified temperature difference

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The stratified temperature difference will cause an additional stress in the cases where temperature is cycling.

Enter the maximum difference in stratified temperature in the entire piping system. The additional stress will be
added to the expansion stress.

Cycle Multipliers
Increase the number of cycles for the entire system by a multiplier.

· Cycle Multiplier
· Cumulative Damage Files Cycle Multiplier

Cycle Multiplier
This increases the number of cycles entered in the main window's grid.

Cumulative Damage Files Cycle Multiplier

When cumulative damage files are added into the program, the number of cycles can be increased by this factor.

Stress tolerance to print

This is a reporting capability. If a stress difference, or absolute stress is less than the value in this box, it will not
be shown in the report. The default is 2 psi.

Line operates with gas at pressure

If the line operates with gas at pressure, then this might fall into Group 1 or Group 2 type of gas.

If this box is checked and the fluid category is hazardous, then the piping system will fall into Category III, which
is a dangerous chemical inside the piping system. More conservative values will be given for crack growth and
damage calculations.

If the fluid category is not hazardous, but the diameter of the pipe is large and the pressure is large, then this can
be considered hazardous also, as compressed gas is dangerous.

Avoid leak at all cost

This option is not currently used.

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Inspection
Inspection points can be assigned to the piping system at specific nodes to evaluate Fitness For Service for cracks
and local thin areas.

· Inspection Points Data

· Inspect per Fluid Service
· Inspect per Severe Cyclic Service
· Weld root passes generally NOT inspected
· Weld root passes 100% visually inspected
· All welds 100% visually inspected
· All welds 100% radiographed

Inspection Points Data

Enter crack-like flaws and local thin areas at specific nodes for evaluation.

· FFS Material Properties

· Local Thin Area (LTA) Properties

When pressing the button, the window below will appear.

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Use inspection points: Select this box to enter the crack and local thin area flaws in the piping system.

The toolbar below allows to add and remove flaws.

The icons below add or remove rows from the grid. Use the Add icon to add a flaw at a different node location.

To add flaws at the same node, but at different inspection times (Inspection Years column), then the icons below
can be used. A maximum of 5 different flaw definitions can be added at the same node in the same row. If more
than 5 are needed, a second row with the same node number can be added.

The remove column icon will remove the selected flaw within the same row.

The data in the grid is shown below. Note that Flaw Depth and Length are optional, defaults will be used as long
as the inspection number of years is entered.

Use - Select this cell to use the particular flaw.

Node Number - Enter the node number where the flaw is located.
Inspection [Yrs] - enter the number of years into the start of operation the first inspection took place.
Flaw Depth - Enter the crack-like flaw depth at the given node. If not entered, default will be used.
Flaw Length - Enter the crack-like flaw length at the given node. If not entered, default will be used.
Mat'l Props - Fitness for Service properties. More information in the FFS Material Properties topic.
Use LTA - Check to analyze for local thin areas (LTA) at the given node. The data within LTA Props must be entered.
LTA Props - Local Thin Area properties for the given node. More information in Local Thin Area (LTA) Properties
topic.

When adding mulitiple inspections for the same node number, the following rules must apply, otherwise the
inspection case will be ignored.

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1. The second flaw case cannot have the number of years be the same or equal to the previous inspection. In the
example above, if a second inspection case is to be added, the number of years cannot be 1, or a number less than
1.
2. The flaw length and depth must be at least the same value as the previous inspection point. Cracks cannot get
smaller over time.

FFS Material Properties

All the values in the Fitness for Service properties are optional. Defaults will be used if not entered.

· Optional
· Advanced

Units can be changed through the menu item shown below:

Default is English units.

Optional
Define the optional data for Fitness For Service evaluation.

· Probability of failure
· Primary load certainty
· Nominal thickness at flaw
· Material's Nil Ductility

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· Local radius of curvature

· Number of operating cycles
· Ignore partial safety factors
· Flaw is exposed to a marine environment
· Flaw region has been post weld heat treated
· Secondary loads are applied dynamically

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Probability of failure

Defines the probability of failure for the user defined flaw. This input is only used for the analysis of crack like
flaws. The probability of failure is used in conjunction with the “primary load certainty” input to determine the
partial safety factors applied to the primary and secondary stresses (and other user defined flaw variables).
Higher probability of failure values will result in greater partial safety factors, effectively increasing the design
margins in the fitness for service evaluation and providing for a “safer”edesign.

· High is the most conservative assumption (lowest risk of failure).

· Medium is slightly less conservative (moderate risk of failure).
· Low represents the lowest margin against the mean failure curve (higher risk of failure)

The default value of HIGH equates to a margin of 4 standard deviations below the mean failure curve. Medium
represents approximately three standard deviations below the mean failure curve. Low represents approximately
two standard deviations below the mean failure curve.

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Primary load certainty

The primary load certainty relates to the coefficient of variation (COV) related to the uncertainty in the primary
stress distribution. This input is only used for crack like flaw evaluations. Three options are available for the
primary load certainty input:

1. Well Known – primary loads and stresses at the flawed zone are computed or measured and are well known. This
option corresponds to a COV = 0.10.

2. Reasonably Known – primary loads and stresses in the flawed zone are computed or measured and are reasonably
well known. Here, the uncertainty is due to the possible variation in the loading or calculation methods.

3. Uncertain / Random Loadings – calculated or measured primary loads and stresses are significantly uncertain. The
uncertainty is a result of the unknown or random nature of the applied

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Nominal thickness at flaw

Typically, the nominal thickness at the flaw is determined by the thickness at the flaw as defined in the finite
element model. However, the user may override the fiite eeemeit modeels thiiciess suih that the ftiess sor
service calculations use the options “Nominal Thickness at Flaw” value. Note that this thickness will not modify
the local thickness in the finite element model, it is only used in the fitness for service post processing
calculations.

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Material's Nil Ductility

The nil ductility temperature is only used for crack like flaw evaluations. Defines the nil ductility temperature for
the material of construction in which the flaw is located. Used as the “reference temperature”, and defined as the
temperature corresponding to a Charpy impact value of 15 ft-lb for carbon steels and 20 ft-lb for Cr-Mo steels.
The Nil Ductility Temperature is not used for stainless steels.

Note that if the nil ductility is actually zero degrees, then a value near zero but not exactly zero should be
specified (for instance 0.1). A value of zero will not initialize the input and results in a default nil ductility value
for the materials.

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Local radius of curvature

Defines the local radius of curvature of the vessel or pipe at the location of the user defined flaw. If no input is
provided, then the program will use the pipe's diameter to compute the local radius of curvature.

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Number of operating cycles

Defines the estimated number of operating cycles for which the flaw will be exposed to during the anticipated
future service life. The number of operating cycles is not the total cycles for the equipment. Instead, it is only the
number of future cycles to which the flaw is exposed.

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Ignore partial safety factors

The partial safety factors are used to provide additional margin against failure in light of uncertainties in the
loadings and calculations. On occasion, the analyst is more concerned with reducing the safety margin and
estimating a more realistic margin against failure. In such cases, the user may evaluate the flaw without the use of
the partial safety factors. Note that this input is only used for the evaluation of crack like flaws.

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Flaw is exposed to a marine environment

Used for crack growth rate calculations only; does not affect the local thin area computations. Increases the crack
growth rate for both stainless and carbon steels per API 579 F.5.3 by 4.4 times.

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Flaw region has been post weld heat treated

This factor is only used in the evaluation of crack-like flaws and will reduce the effect of residual stress when the
flaw is in the proximity of a weld. If PWHT has been performed the residual stresses in the weld are reduced to
20% of their non-PWHT values.

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Secondary loads are applied dynamically

Only used for the evaluation of crack like flaws. Used when some portion of the operating load or secondary
stress is applied dynamically. In this case the KIC value will be adjusted based on the temperature, and the
Dynamic Ramp loading time. The user can override this calculation by entering the Dynamic Critical fracture
toughness at operating temperature if a better value is available.

If selected, enter the dynamic time to reach yield.

Advanced
Enter advanced data for Fitness for Service Evaluation.

· Define know material properties

· Fracture toughness values are known
· Use critical J value to calculate toughness
· Use CTOD value to calculate toughness
· Use Chapy impacts to calculate toughness

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Define known material properties

If material properties for the material of construction are known, then select this option to access the material
definition options.

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Facture toughness values are known

KIC value at operating conditions. This value will be estimated by the program based on the type of material input
if not entered. Only used for crack type flaws.

KID value at operating conditions for dynamic loadings. Only used if the “Secondary Loads are Applied
Dynamically” check box is marked in the Optional input tab. If not entered the program will calculate a dynamic
KID based on loading time and temperature. Only used for crack-type flaws.

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Use ciritical J value to calculate toughness

If a J integral value is entered it will be used to compute the KIC per API 579 Appendix F.4.2. Only used for crack-
type flaws.

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Use CTOD value to calculate toughness

If a crack tip opening displacement value is available from a CTOD test of the material then this value may be
entered as per API 579 Appendix F.4.2.

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Use Charpy impacts to calculate toughness

Enter the Charpy energy at operating temperature if available. This value can be converted into the KIC value to be
used in crack-type flaw evaluations.

Local Thin Area (LTA) Properties

Local Thin Areas (LTA) will be defined in this window.

· Local point-to-line load location (bar/steel support)

· Local thin area

Units can be changed through the menu item shown below:

Default is English units.

Local point-to-load location

Select this box if an evaluation needs to be performed for a corroded or uncorroded pipe sitting on a bar or steel
support.

Maximum allowable normal loads will be obtained from the pipe stress results and compared to maximum
allowed normal load based in Pipe Stress Engineering by Peng and Peng.

The membrane and bending stresses due to the loads will also be calculated and compared to the yield strength
Sy. Preventing yield is a good approach, if the pipe remains elastic, then at shut downs the pipe will return to its
original shape.

The results are shown below for every load case in a system. The membrane, bending and membrane+bending
stresses are evaluated as well as the normal force on the pipe.

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Local thin area

If the local thin area box is checked, then the data below should be entered.

· Average thickness of thinned zone

· Longitudinal length of thinned zone
· Circumferential extent of thinned zone
· Results

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Average thickness of thinned zone

Enter the average thickness of the thinned zone. Note that to be more conservative, the minimum thickness of the
zone can be entered. This value will be used to adjust the stress at the node location to evaluate the local thin
area.

The adjusted stress is the stress form the pipe stress results multiplied by the ratio of section modulus from
uncorroded to corroded. The thinner the pipe, the larger the adjusted stress.

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Longitudinal length of thinned zone

Enter the longitudinal extent of the thinned area. Note that if the extent is larger than the SQRT(RT), there R is the
midsurface radius and T is the thinned thickness, then a buckling calculation is performed. In the cases where
there is a large thin area, special considerations need to be taken for buckling.

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Circumferential extent of thinned zone

Enter the circumferential extent in degrees for the local thin area.

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Results
Local thin area results in this program will perform a buckling analysis if the extent of the local thin area in the
longitudinal or circumferential direction is greater than SQRT(RT), where R is the midsurface radius and T is the
thinned thickness. When the extent of the thin area is large, buckling considerations must be made in order to
ensure that the pipe surface will not buckle under internal or external pressure, or due to external loadings.

The report below shows an overstress after adjusting the stress by the thinned section modulus. The report shows
every load case in the system with the original stress (uncorroded) and the adjusted stress (corroded), along with
a buckling allowable.

Pressure calculation must also be considered for local thinned areas. Most pipe stress programs do not perform
a pressure calculation in the code compliance. The axial force due to pressure is considered, but the hoop stress
due to pressure is not. The hoop stress is calculated and given in the report below. The allowable is 2/3 Sy.

Inspect per Fluid Service

If this box is selected, the fluid category will take more consideration in determining the amount of time for
inspection.

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Depending on the fluid service, the inspectors require that welds are inspected visually or with radriograph. What
this option does, is to select the options for weld inspection based on the fluid category selected.

Inspect per Severe Cyclic Service

This option is not currently used.

Weld root passes generally NOT inspected

Select this box if the welds are not inspected. This will significantly decrease the amount of time (about 3 times)
before the welds need to be inspected.

This option will be used if the options to inspect per fluid service is not selected.

Weld root passes 100% visually inspected

If the weld roots are visually inspected, then select this box. This option will be used if the option to inspect per
fluid service is not selected.

If selected in conjunction with the options:

All welds 100% visually inspected and All welds 100% radiographed, then the time to inspect welds will increase
by approximately 10%.

If the options are not selected, then the inspection time will be decreased by approximately 50%.

All welds 100% visually inspected

Select this box if the welds are 100% visually inspected.

If this box is selected together with Weld root passes 100% visually inspected and All welds 100% radiographed,
then the time to inspect welds will be increased by approximately 10%.

This option will be used if the option to inspect per fluid service is not selected.

All welds 100% radiographed

Select this option if the welds are 100% radiographed. This option will be used if the option to inspect per fluid
service is not selected.

If this option is selected then the time to inspect welds will be increased by 10% if the option All welds 100%
visually inspected is selected.

Current State
The time in the current state is used to give time recommendation on when to inspect the piping system at critical
locations.

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· Total service life

· Current time in operation
· Time before next shutdown

Total service life

Enrer the total service life of the plant. if left blank a total of 40 years will be assumed.

The total life of the plane is used in conjunction with the current time in operation to predict the total number of
cycles from startup until now.

Current time in operation

Enter the total time in operation for the piping system.

This will be used with the total plant life to determine the total number of cycles up-to-date.

Time before next shutdown

Enter the number of years until the next shutdown. Fractions can be entered.

This number will be used to predict the probability of finding an indication at the next shutdown.

Occasional Load Determination

Depending on the type of occasional loads, some further calculations may be required.

· Occasional loads can be due to waterhammer

· Occasional loads can be due to earthquake
· Occasional loads can be due to blast
· Line is subject to pulsating pressure loads

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Occasional loads can be due to waterhammer

Enter whether the occasional loads may be due to waterhammer.

If occasional loads are due to any of the following, additional safeguarding must be performed by the engineer
since stresses are not well qualified.

· waterhammer
· earthquake
· blast
· pulsating pressure loads

Occasional loads can be due to earthquake

Enter whether the occasional loads may be due to earthquake.

If occasional loads are due to any of the following, additional safeguarding must be performed by the engineer
since stresses are not well qualified.

· waterhammer
· earthquake
· blast
· pulsating pressure loads

Occasional loads can be due to blast

Enter whether the occasional loads may be due to blast loads.

If occasional loads are due to any of the following, additional safeguarding must be performed by the engineer
since stresses are not well qualified.

· waterhammer
· earthquake
· blast
· pulsating pressure loads

Line is subject to pulsating pressure loads

Enter whether the occasional loads may be due to pulsating pressure loads.

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If occasional loads are due to any of the following, additional safeguarding must be performed by the engineer
since stresses are not well qualified.

· waterhammer
· earthquake
· blast
· pulsating pressure loads

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