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Fitness-for-Service Assessment of Local Thin Area in a Line Pipe

Article in Journal of Failure Analysis and Prevention · April 2021


DOI: 10.1007/s11668-021-01161-3

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J Fail. Anal. and Preven.
https://doi.org/10.1007/s11668-021-01161-3

TECHNICAL ARTICLE—PEER-REVIEWED

Fitness-for-Service Assessment of Local Thin Area in a Line Pipe


Sh. Zangeneh

Submitted: 15 February 2021 / in revised form: 20 March 2021 / Accepted: 14 April 2021
Ó ASM International 2021

Abstract Fitness-for-service (FFS) assessment of a line integrity evaluation are critical factors to provide enough
pipe that contained a metal loss was performed in this reliability for safe operations.
investigation. The initial inspection found that a leaking Fitness-for-service (FFS) assessment is a quantitative
hole in the pipe caused shut down of the whole line. FFS tool to evaluate the ability of damaged equipment that has
assessment in level 3 based on API579-1/ASME FFS-1 suffered from one or more types of damage to remain in
was carried out by considering different damage mor- operational service. FFS was used at first to evaluate
phologies including general corrosion, local thin area welding defects in nuclear-pressurized components and
(LTA) and pitting corrosion. The type of damage was then spread, over the past two decades, to equipment used
determined as LTA due to corrosion under deposition. To in the refinery industry [4, 5]. FFS assessment is routinely
evaluate FFS in level 3, finite element method analysis was conducted on three different levels. Level 1 is more con-
utilized, and the results showed that the pipe under con- servative related to level 3, which in turn leads to more
taining the damage had remaining strength factor of 0.91 conservative assessment as compared to level 3 resulting in
which means that the pipe should return to service until realistic outputs. In other words, each level of assessment
next schedule inspection (around 3 years) based on future provides a balance between the skill of the practitioner, the
corrosion allowance. degree of conservatism, and the intricacy of the analysis. In
general, FFS assessment decides to either keep damaged
Keywords Fitness for service assessment  Corrosion  equipment in-service, re-rating for a specified remaining
Local thin area  Finite element analysis life, or to be completely retired leading to replacement.
When a damaged component is kept in-service, FFS
determines its remaining life under original design or re-
Introduction rated operational conditions. FFS assessment methods
evaluate different damage types such as general and
Huge amounts of energy are delivered by pipelines around localized corrosion, pitting [6] (widespread or localized),
the world, hence their integrity is essential to energy supply hydrogen-induced damage, shell distortions [7], weld
[1]. Piping systems in the petrochemical industry are misalignment [8], and crack-like flaws including environ-
generally inspected for some given damage types such as mental cracking, dents [9], gouges and laminations.
blistering [2], corrosion [3], etc. In a damaged piping Pressure components such as pressure vessels, piping
system, it is essential to predict accurately failure pressure and storage tanks suffer from some common corrosion
to maintain safety of these components. As the pipeline problems known as local thin area (LTA) [10, 11]. LTA is
system ages over time, detailed assessment procedures for widespread corrosion damage in pressurized components
which frequently occurs in petrochemical industries and
refineries. These defects are usually found as a colony
Sh. Zangeneh (&)
which results in lower failure pressure as compared to
Department of Materials and Textile Engineering, Faculty of
Engineering, Razi University, Kermanshah, Iran when they are found isolated. This reduction of failure
e-mail: Shzangeneh@razi.ac.ir pressure is largely attributed to the interaction of these

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J Fail. Anal. and Preven.

defects. The size of LTAs will also increase, and this In this study, FFS assessment for a line pipe containing
increase leads to LTA size of a critical point where the LTA has been performed in level-3 and the stresses have
component will not tolerate the amount of damage, finally been analyzed using finite element analysis (FEA) to
leading to rupture. Thinning profile in the LTA might be evaluate the acceptability of the equipment and moreover
rectangular with a constant thinning thickness or circular determine the remaining life of the damaged pipe when
surface thinning profile or it might be arbitrary shaped LTA is located at a welding line or remote from it.
thinning defects. This inventible failure leads to destruction
of the component and finally stop production, which
imposes increased cost on petrochemical plants and Background Condition of the Damaged Pipe
refineries. To avoid failure due to LTA, a simple process is
design thickness used to indicate which equipment should Table 1 lists the main design operation data of the damaged
be safe for service before reaching this value. Remaining pipe with LTA. A corrosion rate of 1 mm per year was
life of the damaged components containing LTA is then determined from the wall thickness reading.
calculated using the time to reach minimum thickness or Figure 1a shows the inside of the damaged pipe,
tmin. This method is simple and can be used for general including many deposits in the lower part of the pipe. After
thinning, whereas remaining strength factor (RSF) (Eq 1) cleaning, numerous LTAs along with pitting corrosion
uses in API579-1/ASME FFS-1 is a reliable indicator to were revealed at the 6 o’clock position of the pipe. Fig-
determine the eligibility of the damaged component con- ure 1b shows several LTAs along with a hole that caused
taining LTA. leakage. The inspection grid size to measure wall thickness
LDC was 5 mm in the circumferential direction and 8 mm in the
RSF ¼ ðEq 1Þ length direction. This grid covered the lower part of the
LUC
pipe in the metal loss region. The UT measurements
where LDC is the limit or plastic collapse load of the showed that the LTA was limited to the region between
component with flaws or damaged component and LUC is 150° and 170° and based on the obtained results the most
the limit or plastic collapse load of the undamaged com- metal loss occurred at 180° (6 o’clock). The minimum
ponent. RSF could be determined by using linear elastic remaining thickness at one of the main LTA was 5.92 mm;
stress analysis; however, this method provides only a rough the nominal thickness was 8.18 mm. After internal
approximation of the safe load without failure. In contrast, inspection of the damaged pipe, a decision needed to be
nonlinear stress analysis gives a more accurate estimate of reached whether the pipe could be returned to service, or
the load-carrying capacity. repair was required. Moreover, the next scheduled
A survey of literature shows numerous studies on the inspection should be dated for safe operation without any
FFS assessment and accepting damaged equipment criteria unforeseen event like this one.
of pressurized components suffering from LTA. Attia et al.
[12] studied various criteria based on API579-1/ASME
FFS-1 for accepting damaged equipment due to metal loss. Verification of Simulation Technique
It was found that continued operation at the designed
internal pressure caused a shorter lifetime compared to To verify the established simulation procedure used in this
pressure de-rating for extended operation. The remaining work, a local thinning area based on Yamaguchi [14] work
life of the damaged component was estimated through was modeled. The geometry structure of the verification
global and local failure criteria. Tahara et al. [11] deter- model was a pipe with 900 mm in length, 8.2 mm in
mined the thickness reading for FFS assessment plays an thickness, and the outer diameter of 216.3 mm (Fig. 2a).
important role, as accurate thickness reading of LTA The material properties and mechanical boundary condi-
damage has a significant role in the FFS results. Peng et al. tions in this analysis were selected similar to Yamaguchi
[13] studied the interaction effect of multiple LTAs, and [14] work during burst test. The geometry of the LTA was
they studied varying parameters such as different 85 9 85 mm2 as a square wall thinning with the remaining
arrangements, loading conditions, and relative LTA depth
on FFS assessment. Yamaguchi [14] studied the burst
pressure of a damaged pipe containing LTA with different Table 1 Design data of the damaged pipe used in this research
shapes to accurately estimate the burst pressure by FEA. It Operational Design Outside Original
was found that without consideration of the size and the pressure pressure diameter thickness
shape of the LTA, the burst pressure calculated by FEA (MPa) (MPa) (mm) (mm) Material
completely agreed well with the test results.
1.1 1.5 203.2 8.18 ASTM A53 GB

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Fig. 1 (a) Inside view of the


damaged pipe showing severe
deposition, (b) The part of
corroded pipe replaced
containing leaking hole

Fig. 2 (a) Model of a damaged pipe based on [14] showing LTA at 12 o’clock position, (b) and (c) von Mises equivalent stress distribution at
plastic instability point, (d) Displacement vs. internal pressure of the modeled pipe with around Pf = 28.3 MPa

thickness of 4.18 mm. The burst pressure corresponding to The point corresponding to PF is the endpoint of the curve.
PF calculated by FEA is defined as the internal pressure at The results show that the PF before diverging for the
which the wall thinning strain diverged. Figure 2b and c damaged pipe is around 28.3 MPa, and this value based on
shows von Mises equivalent stress distribution at plastic Yamaguchi [14] work is 29 MPa, demonstrated that the
instability point when the solution diverged. The maximum established procedure used here is verified well.
effective stress at the plastic instability point in the dam-
aged pipe is 580 MPa, equal to the true ultimate tensile
strength of the pipe material. Figure 2d shows variations of
displacement with internal pressure P in the damaged pipe.

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J Fail. Anal. and Preven.

Result and Discussion

Level-3 FFS Assessment

To perform the level-3 FFS assessment of the corroded


pipe, stress analysis should be carried out to assess
equipment acceptability and remaining life estimation. 3D-
nonlinear FEA was utilized to determine the failure pres-
sure of a pipe with LTA. For an accurate analysis, FEA
should accurately represent the model. That is, the model
geometry, the material properties, and the applied loads
need to be realistically considered. In general, the shape of
a LTA corrosion could be simplified, however, the maxi-
mum dimensions of the LTA such as axial length,
circumferential width and maximum LTA depth should be
accurately measured to obtain realistic results. The mini-
mum value of the wall thickness adjacent to the LTA was
utilized to represent the undamaged component thickness.
For this purpose, thickness variation obtained using UT
Fig. 4 True stress-strain curve of ASTM A53 GB steel obtained by
scans with consideration of future corrosion allowance MPC model
(FCA) was mapped directly into the FE mesh (as shown in
Fig. 3a) and linearly interpolated at given element cen- model at the operation temperature and utilized in this
troids by square shell element with type S4R (4-node current analysis.
general-purpose shell, reduced integration) and a minimum rt
of 11 integration points through the shell thickness. In this e t ¼ þ c1 þ c2 ðEq 2Þ
Ey
analysis, shell elements with a nominal thickness of 5.92
mm were used to model undamaged regions, and the 1 et ð 1 Þ
c1 ¼ ð Þ m1 ð1  tanh½HÞ ðEq 3Þ
damaged regions were modeled using thickness variations 2 A1
at exact location of LTA damage. Figure 3b shows thick- 1 et ð 1 Þ
ness variations of the damaged pipe from 5.92 mm to 3.98 c2 ¼ ð Þ m2 ð1  tanh½HÞ ðEq 4Þ
2 A2
mm. Nonlinear effects in the current investigation because
rys ð1 þ eys Þ
of large displacement and material nonlinearity (NLgeom) A1 ¼   ðEq 5Þ
were also considered in the FEA model. ðln 1 þ eys Þm1
The damaged pipe investigated herein was made from ruts expðm2 Þ
ASTM A53 GB steel. API579-1/ASME FFS-1 recom- A2 ¼ ðEq 6Þ
mm2
2

mends that for elastic-plastic analysis, the material


behavior should be modeled as an elastic-plastic material
by MPC relation through Eqs 2 to 10. Figure 4 shows the
nonlinear true stress-strain curve obtained from MPC

Fig. 3 (a) Modeling of the damaged pipe by shell element contained LTA region (b) LTA damaged area inside of the corroded pipe

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J Fail. Anal. and Preven.

ln½R þ ðep  eys Þ undamaged pipe when the solution diverged. It is obvious
m1 ¼   ðEq 7Þ
ln½1þep  that instability occurs in the whole pipe. Figure 6b shows
ln ln 1þe von Mises stress in the damaged pipe in plastic instability
½ ys 
  points in the damaged pipe. The maximum effective stress
2 rt  ðrys þ Kðruts  rys ÞÞ at the plastic instability point in the damaged pipe is 530
H¼ ðEq 8Þ
Kðruts  rys Þ MPa which is equal to true ultimate tensile strength of the
pipe material. This maximum plastic instability was
K ¼ 1:5R1:5  0:5R2:5  R3:5 ðEq 9Þ
obtained because of the limited extent of the plastic
rys
R¼ ðEq 10Þ instability zone. However, this value in the undamaged
ruts pipe barely reached 495 MPa in the whole section of the
The FEA was performed using a nonlinear static stress pipe, which is lower than the damaged pipe. This could be
analysis incorporated material plasticity with isotropic due to that the instability in the uncorroded pipe is global;
hardening and large displacement theory. The von Mises however, it was localized in the pipe containing LTA. As
equivalent stress variations against inside pipe pressure one can see from the results, level-3 FFS assessment can
should be reported at a position within the damaged area easily estimate the location of final failure in the corroded
containing high von Mises equivalent stress. To perform pipe as well as the scenario of failure when the pressure
this analysis based on API579-1/ASME FFS-1, global and reaches the plastic instability point. According to the ori-
local criteria should be checked. For this purpose, an iter- entation of stress in the corroded pipe (Fig. 6b), failure will
ative nonlinear solver in Abaqus software based on a occur along the longitudinal direction of the damaged pipe.
modified Newton-Raphson scheme was utilized. The The results show that the PF before diverging for the
sequence of applied loads was chosen to show the service undamaged pipe is 27.6 MPa and the value for the dam-
condition. In this case, body force (defined as the weight of aged pipe will be 25.1 MPa. Remaining strength factor
damaged pipe including inside fluid) was applied at the first (RSF) is defined by Eq 1, therefore, by comparing the
step and then the damaged pipe was subjected to the results, RFS value is 0.91.
pressure load and end cap force, which was increased In this investigation, level 3 assessments for global and
incrementally up to the point that the pipe material showed local failure were carried out based on Eqs 11 and 12,
plastic instability and the solution became diverge. The respectively. In these equations, P and D parameters are
loading increment was chosen sufficiently small to ensure internal pressure and deadweight of the components (in the
convergence. current research, D is the weight of damaged pipe includ-
Figure 5a shows the result of maximum von Mises stress ing inside fluid), respectively. It should be noted that the
variations within the LTA region against incremental liquid static head, fluid momentum effects, earthquake
loading (inside pressure along with end cap force). In loads, snow loads, wind loads, and thermal loads are not
general, the von Mises stress variations with increasing included in the current investigation. In this case, internal
load show three quite distinct stages named here I to III. pressure was considered as the significant load that causes
The first, or stage I, is a linear response up to near yield the plastic collapse of the damaged pipe. If one of the
stress. The second, or stage II, initiates at the yield point in local/global loads causes plastic instability, therefore, the
which plasticity gradually spreads through the LTA while pipe will be unsafe at the applied pressure.
the maximum stress remains nearly constant because of the
bðP þ DÞ ðEq 11Þ
constraint from the undamaged area (Fig. 5b–e). Finally,
the third, or stage III, begins when the stress in the entire 1:7ðP þ DÞRSFa ðEq 12Þ
LTA far exceeds the material’s yield strength. At this stage,
where b or load factor coefficient is a parameter varied
the whole ligament of LTA deforms plastically, but col-
based on the construction code which in this investigation
lapse does not occur immediately because of strain
b is 3RSFa. Figure 7a shows variations of displacement
hardening.
with internal pressure P in the damaged pipe. The point
The von Mises equivalent stress through the minimum
corresponding to PF is the end point of the curve. In
ligament of the LTA can be used to determination of the
addition, Pdesign and global failure pressure (indicated by
failure pressure Pf. The predicted failure pressure Pf is the
convergence requirement) defined based on Eq 11 indi-
pressure that causes the averaged von Mises stress in the
cated in the figure by dash lines. As one can see, PF is far
remained ligament to be equal to the material’s true tensile
beyond the criteria requirement for global failure pressure.
strength from a uniaxial tensile test. Figure 6a and b show
Therefore, the damaged pipe meets the required acceptance
the von Mises stress distribution in the undamaged/dam-
criteria against global plastic collapse.
aged pipes at plastic instability points, respectively.
Figure 6a shows this stress at plastic instability point in the

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Fig. 5 (a) von Mises equivalent stress variations within the LTA region against incremental loading, (b–e) von Mises equivalent stress
distribution in stage II showing plasticity spreads through the LTA region

Fig. 6 von Mises stress distribution in the (a) undamaged (b) damaged pipes at plastic instability

In addition, Fig. 7b and c shows the von Mises stress To assess the damaged component for global and local
distributions at the designed and converge-required loads, criteria, some similarities exist. The pipe model, material
respectively. As one can see, the maximum peak stress in property, and boundary conditions (BCs) are the same.
design load could reach 41.3 MPa and in convergence the However, the applied loads and acceptance criteria utilized
required load is around 82.6 MPa, which is much less than for the damaged component are quite different. Therefore,
yield strength of the pipe material. the procedure established for protection against local

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J Fail. Anal. and Preven.

Fig. 7 (a) Convergence behavior of the damaged pipe, von Mises stress distribution at (b) Design load (c) Convergence requirement

failure as a result of LTA in the damaged pipe is the same shows variations of damage with internal pressure P in the
as the global model. However, the required acceptance damaged pipe. As one can see, no damage appeared at
criteria against local plastic collapse, which is represented design load or convergence requirement as indicated by
by Eq 12, needs a lower load factor. Since this criterion dash lines. Figure 8b shows damage distribution in the pipe
will be accepted by lower load factor related to global one, containing LTA, no local damage occurred in the damaged
the corroded pipe is accepted local failure assessment. pipe at design load which is completely confirmed API579-
Limiting triaxial strain (eL ) using Eq 13 was used to define 1/ASME FFS-1 recommendation. API579-1/ASME FFS-1
the damage parameter (d) of LTA under protection against recommend that the strain limit criterion (represented by
local failure. This parameter shows the amount of damage Eq 11) normally does not need to be evaluated in FFS
extent in the corroded pipe with an acceptance value of less assessment if the component design is in accordance with
than or equal to unity, investigated in this current research. the applicable construction code, and moreover the pres-
     ence of a flaw does not result in a significant strain
asl r1 þ r2 þ r3 1
eL ¼ eLU exp   concentration. However, this damaged value as shown in
1 þ m2 3re 3
Fig. 8c at plastic instability point became significant and its
ðEq 13Þ value became more then unity.
epeq
d¼ ðEq 14Þ
eL Remaining Life Estimation
where r1, r2, r3 are principal stresses, re is equivalent
stress,epeq is the total equivalent plastic strain. Figure 8a An essential question remaining unanswered in this
investigation is whether the damaged pipe could be

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J Fail. Anal. and Preven.

Fig. 8 Damage value based on local failure damage at (a) Design load (b) Instability point of the corroded pipe

increases with increasing internal pressure up to PF point in


which effective stress reached to true ultimate tensile
strength. Different FCAs in the damaged pipe can tolerate
different internal pressures. As the damage in the pipe due
to FCA increases the amount of maximum internal pressure
in the damaged pipe due to loss of pressure carrying
capacity of the pipe decreases. The plots show that this
value for FCA of 1 mm is 21.8 MPa and for FCA of 3 mm
reaches the value of 11 MPa. Therefore, the pipe will be
safe for the FCA value of 3 mm under both global and local
instability criteria.
Figure 10a–c shows damage obtained from Eq 14 at the
convergence requirement for the corroded pipes with dif-
ferent FCAs. As it is obvious, with increasing FCA from
Fig. 9 Displacement vs. internal pressure of the corroded pipe for 1mm to 3mm, the damage in the LTA increases up to
different FCAs around 0.3 which is still lower than unity. It should be
noted that when the RSF was less than 0.6, the estimated
returned to service until the next scheduled inspection (3 burst pressure was assessed as dangerous.
years). To answer this question, and therefore estimate
remaining life of the corroded pipe with reported MPY Welding Residual Stress Effect
equal to 1mm, displacement-internal pressure plots with
different future corrosion allowance (FCA) were deter- Since some of these LTAs with similar dimensions were
mined (Fig. 9). According to the plot, displacement located randomly in the welding line, the welding residual

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Fig. 10 Damages of the corroded pipes at convergence requirement for FCA (a) 1mm (b) 2mm (c) 3mm

stress (WRS) should be considered as an input data to The averaged von Mises equivalent stress calculated from
perform proper FFS assessment. For this reason, the pre- the results of thermal analysis is shown in Fig. 11b.
viously analyzed LTA was re-assessed while assumed to be Figure 12a shows variations of displacement with
located in the welding line, in order to understand the effect internal pressure P in the damaged pipe in which it was
of WRS on plastic collapse load. assumed the LTA was located at the weld line. The plastic
To understand the effect of WRS on LTA damage, collapse load corresponding to PF is nearly equal to the PF
Abaqus software was utilized to simulate welding tem- when the LTA is remote from welding line. It seems that
perature by the use of Goldak equation (Eq 15). The residual stress induced by welding has no severe effect on
Goldak equation uses double ellipsoid heat flux to model the PF value. As one can see, PF is far beyond the criteria
the shape of arc welding in which heat flux shows a requirement for global failure pressure. Therefore, the
maximum value at the center and decreases to the ellipse damaged pipe containing a weld line meets the required
edge. In this model, distribution of transient volumetric acceptance criteria against global plastic collapse. In
heat flux was implemented into Abaqus through DFLUX addition, Fig. 12b–e shows von Mises stress distribution at
user-subroutine. the location of LTA which is crossed through the weld line.
pffiffiffi As one can see, by increasing internal pressure the same
6Q 3
qðx; y; z; tÞ ¼ pffiffiffi trend in displacement vs. internal pressure curve appears.
abcp p
2
However, the lower pressure in which the damaged pipe
=a2 3ðyðR cos hþy0 ÞÞ2 =b2 3ðzz0 Þ2 =c2
e3ðxðR sin hþx0 ÞÞ e e should be in elastic state shows severe residual stress, while
ðEq 15Þ by increasing internal pressure this residual stress disap-
pears due to concentration of stress because of LTA
where Q is heat input, R defines the distance of the welding damage.
heat source from the pipe center, h is the radial angle
changes through circumferential direction. Parameters a, b,
and c (6, 3.5 and 4 mm, respectively) are the semi-axes of Conclusion
the ellipsoidal weld pool in x, y, and z directions, respec-
tively. Upper limit in Q based on API 579/ASME FFS-1 This research was carried out to assess the acceptability of
was chosen in this current investigation, since no record of a pipe with real LTA shape along with remaining life
welding parameters was found. The nodal temperature estimation by consideration of MPY of 1mm. Level-3 FFS
(NT11) distribution during welding is shown in Fig. 11a. assessment was considered because this level provides the
most accurate results and provides the best estimate of

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Fig. 11 (a) Temperature (NT11) distribution during welding, (b) Welding Residual Stress (WRS) distribution after welding

Fig. 12 (a) Displacement vs. internal pressure of the corroded pipe containing welding line (b–e) von Mises stress distribution at the different
internal pressure indicated by arrows

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J Fail. Anal. and Preven.

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