Professional Documents
Culture Documents
The API 579 Fitness-for-Service Standard - The Current State of Technology and A Ten Year Look Ahead
The API 579 Fitness-for-Service Standard - The Current State of Technology and A Ten Year Look Ahead
2
Introduction
• The ASME and API construction codes do not provide
rules to evaluate a component containing a flaw or
damage that results from operation after initial
commissioning
• Fitness-For-Service (FFS) assessments are quantitative
engineering evaluations that are performed to
demonstrate the structural integrity of an in-service
component containing a flaw or damage
• API 579 was developed to evaluate flaws and damage
associated with in-service operation
• API 579 assessment procedures were not originally
intended to evaluate fabrication flaws; however, these
procedures have been used for this purpose by many
Owner-Users
3
Introduction
• If the damage mechanism cannot be identified, then a
FFS assessment should not be performed per API 579
– Identification of damage mechanism is the key
component in the FFS assessment
– Firm understanding of the damage mechanism is required
to evaluate the time-dependence of the damage
– Time-dependence of damage is required to develop a
remaining life and inspection plan
• API 579 provides guidance for conducting FFS
assessments using methods specifically prepared for
equipment in the refining and petrochemical industry;
however, this document is currently being used in
other industries such as the fossil utility, pulp & paper,
food processing, and non-commercial nuclear
4
API 579 Development Background
API’s Definition of Fitness-For-Service
5
API 579 Development Background
Need for FFS Standardization
6
API 579 Development Background
MPC FFS JIP Program Overview
7
Overview of API 579
General
8
Overview of API 579
General
9
Overview of API 579
General
10
Overview of API 579
Contents
11
Overview of API 579
Contents
Main Sections
• Section 1 - Introduction
• Section 2 - FFS Engineering Evaluation Procedure
• Section 3 - Assessment of Equipment for Brittle Fracture
• Section 4 - Assessment of General Metal Loss (tm < tmin - large area)
• Section 5 - Assessment of Localized Metal Loss (tm < tmin - small area)
• Section 6 - Assessment of Pitting Corrosion
• Section 7 - Assessment of Blisters and Laminations
• Section 8 - Assessment of Weld Misalignment and Shell Distortions
• Section 9 - Assessment of Crack-Like Flaws
• Section 10 - Assessment of Equipment Operating in the Creep Regime
(Draft version)
• Section 11 - Assessment of Fire Damage
12
Overview of API 579
Contents
Appendices
• Appendix A - Thickness, MAWP, and Stress Equations for a FFS
Assessment
• Appendix B - Stress Analysis Overview for a FFS Assessment
• Appendix C - Compendium of Stress Intensity Factor Solutions
• Appendix D - Compendium of Reference Stress Solutions
• Appendix E - Residual Stresses in a FFS Evaluation
• Appendix F - Material Properties for a FFS Assessment
• Appendix G - Deterioration and Failure Modes
• Appendix H - Validation
• Appendix I - Glossary of Terms and Definitions
• Appendix J - Technical Inquires
13
Overview of API 579
Relationships to Other FFS Standards
14
New Joint API and ASME FFS Standard
15
New Joint API and ASME FFS Standard
16
New Developments for API/ASME 579
• To avoid confusion with other ASME B&PV Codes and
Standards, Sections in API 579 are being renamed to
Parts
• New Enhancements – Existing Sections and New Parts
– Part 5 – Assessment of Local Thin Areas, assessment procedures
for gouges being relocated to Part 12
– Part 7 – Assessment of Blisters and HIC/SOHIC Damage,
assessment procedures for HIC/SOHIC damage have been added
– Part 8 – Assessment of Weld Misalignment and Bulges,
assessment procedures for bulges being modified (in progress),
assessment procedures for dents being relocated to Part 12
– Part 10 – Assessment of Equipment Operating in the Creep Range,
assessment procedures for remaining life calculations for
components with or without crack-like flaws are provided
– Part 12 – Assessment of Dents, Gouges, and Dent-Gouge
Combinations, new Part
– Part 13 – Assessment of Laminations, new Part
17
New Developments for API/ASME 579
• New Enhancements – Existing and New Appendices
– Appendix B – Stress Analysis Overview for a FFS Assessment,
complete rewrite to incorporate new elastic-plastic analysis
methods and fatigue evaluation technology developed for the
ASME Div 2 Re-write Project
– Appendix C – Compendium of Stress Intensity Factor Solutions,
new stress intensity factor solutions for thick wall cylinders,
through wall cracks in cylinders and spheres, holes in plates
– Appendix E - Compendium of Residual Stress Solutions, complete
rewrite to incorporate new solutions developed by PVRC Joint
Industry Project
– Appendix F – Material Properties for a FFS Assessment, new
fracture toughness estimation methods and stress-strain curve
model incorporated
– Appendix H – Technical Basis and Validation of FFS Procedures
– Appendix K – Crack Opening Areas, new appendix covering crack
opening areas for through-wall flaws in cylinders and spheres
18
New Developments for API/ASME 579
19
Overview of API/ASME 579-2006
• Part 3: Brittle Fracture
– Provides guidelines for evaluating the resistance to brittle
fracture of existing carbon and low alloy steel pressure
vessels, piping, and storage tanks
+ Screening of equipment for susceptibility (Level 1 & 2)
+ Detailed assessment using fracture mechanics (Level 3 per
Part 9)
+ Assessment typically performed on a weld-joint by weld joint
basis
– The purpose of this assessment is to avoid a catastrophic
brittle fracture failure consistent with ASME Code, Section
VIII design philosophy; however, it does not ensure
against service-induced cracks resulting in leakage or
arrest of a running brittle fracture
20
Overview of API/ASME 579-2006
• Part 3: Brittle Fracture -
Changes
– Minimal changes to existing
API 579 methodology in
Section 3; Changes in
structure to improve user
friendliness
– Minimum Allowable
Temperature (MAT) -Single
temperature or envelope of
temperature as function of
pressure
– Critical Exposure
Temperature (CET) -Lowest
metal temperature at
primary stress > 8 ksi
21
Overview of API/ASME 579-2006
22
Overview of API/ASME 579-2006
• Part 4: General Metal Loss - Changes
– Minimal changes to existing API 579 methodology
– Change from tmin to trd
Existing t tmin
tmm
New trd
tmm
23
Overview of API/ASME 579-2006
• Part 5: Local Metal Loss
– The assessment procedures of Part 5 are for the analysis
of local metal loss or Local Thin Areas (LTA)
– The procedures of Part 4 are for general (uniform and
non-uniform) metal loss
24
Overview of API/ASME 579-2006
• Part 5: Local Metal Loss - Changes
– Level 1 Assessment
+ Longitudinal plane - screening curve changed to family of
curves f(RSFa, E); groundwork for adapting to different Codes
+ Circumferential plane - screening curve changed to family of
curves f(RSFa, E); Includes 20% of allowable as bending
stress; more conservative
– Level 2 Assessment
+ Longitudinal plane - New Folias factor; no limitation on length
of LTA (was lambda<5)
+ Circumferential plane - Added “circumferential” Folias factor
to analysis; changed acceptability criteria from yield basis to
allowable stress basis
25
Overview of API/ASME 579-2006
n t1 t2 t3 t4
L i
MAWPr i 1
n
Li
P
i 1 i
e
L1 L2 L3 L4
26
Overview of API/ASME 579-2006
• Part 6: Pitting
– The assessment procedures in Part 6 were developed to
evaluate metal loss from pitting corrosion
– Pitting is defined as localized regions of metal loss which
can be characterized by a pit diameter on the order of
the plate thickness or less, and a pit depth that is less
than the plate thickness
– Assessment procedures are provided to evaluate both
widespread and localized pitting in a component with or
without a region of metal loss
– The procedures can be used to assess a damaged array
of blisters as described in Part 7
27
Overview of API/ASME 579-2006
• Part 6: Pitting - Changes
– Level 1 Screening
+ Pitting Charts
* Visual FFS Assessment (similar to ASME Code porosity charts),
* Current Level 1 and existing Level 2 merged into new Level 2
+ Data for Assessment
* Include a photograph with reference scale and/or rubbing of the
surface
* Maximum pit depth
* Cross section of UT thickness scan can also be used
28
Overview of API/ASME 579-2006
• Part 6: Pitting -
Changes
– Pitting Charts
+ FFS by visually
comparing pit chart to
actual damage plus
estimate of maximum
pit depth
+ Pit charts provided for
a different pitting
damages measured as
a percentage of the
affected area in a 6
inch by 6 inch
+ RSF provided for each
pit density and four
w/t ratios (0.2, 0.4, Pitting Chart – API 579 Grade 4 Pitting
0.6, 0.8)
29
Overview of API/ASME 579-2006
• Part 6: Pitting - Changes
– Level 1 Screening
+ Determine ratio of remaining wall thickness to the future
wall thickness in pitted region:
+ Find pitting chart that matches damage and determine RSF
trd wmax
Rwt
tc
where,
t rd thickness away from pitted region
wmax max pit depth
tc future corroded thickness
30
Overview of API/ASME 579-2006
31
Overview of API/ASME 579-2006
• Part 7: Hydrogen Blisters and HIC/SOHIC (New)
– Various forms of damage all related to hydrogen being
charged into the steel from a surface corrosion reaction
in an aqueous H2S containing environment.
– Hydrogen Blistering
+ Hydrogen blisters form bulges on the ID, the OD or within the
wall thickness of a pipe or pressure vessel.
+ Atomic H collects at a discontinuity (inclusion or lamination)
in the steel
+ H atoms form molecular hydrogen which is too large to
diffuse out; pressure builds to excess of YS and local
deformation occurs, forming a blister
– Hydrogen Induced Cracking (HIC)
+ Hydrogen blisters can form at different depths from the
surface. And may develop cracks that link them together.
+ Interconnecting cracks between the blisters often are
referred to as “stepwise cracking”
32
Overview of API/ASME 579-2006
Zero degree
scan overlaid
with 45 degree
shearwave
results
(provided by
Westech
Inspection, Inc.)
33
Overview of API/ASME 579-2006
• Part 7: Hydrogen Blisters and HIC/SOHIC (New)
– Level 2 HIC Assessment
Strength check -
Determine RSF by
considering region
as LTA with
reduced strength
(20%)
Fracture check -
Evaluate HIC as a
crack-like flaw per
Part 9
34
Overview of API/ASME 579-2006
35
Overview of API/ASME 579-2006
36
Overview of API/ASME 579-2006
• Part 9: Crack-Like Flaws
– Crack-like flaws are planar flaws which are predominantly
characterized by a length and depth, with a sharp root
radius, the types of crack-like flaws are
+ Surface breaking
+ Embedded
+ Through-wall
– In some cases, it is conservative and advisable to treat
volumetric flaws such as aligned porosity or inclusions,
deep undercuts, root undercuts, and overlaps as planar
flaws, particularly when such volumetric flaws may
contain microcracks at the root
– Grooves and gouges with a sharp root radius are
evaluated using Section 9, criteria for the root radius is in
Section 5
37
Overview of API/ASME 579-2006
• Part 9: Crack-Like Flaws
– The assessment procedures in Part 9 are based on a
fracture mechanics approach considering the entire range
of material behavior
+ Brittle fracture
+ Elastic/plastic fracture
+ Plastic collapse
– Information required to perform an assessment is
provided in Part 9 and the following Appendices
+ Appendix C - Stress Intensity Factor Solutions
+ Appendix D - Reference Stress Solutions
+ Appendix E - Residual Stress Solutions
+ Appendix F - Material Properties
38
Overview of API/ASME 579-2006
39
Overview of API/ASME 579-2006
• Part 10: Creep (New)
– API 579, Part 10 provides assessment procedures for
pressurized components operating in the creep range
– The temperature above which creep needs to be
evaluated can be established using a Level 1 Assessment
– Assessment procedures for determining a remaining life
are provided for components with and without a crack-
like flaw subject to steady state and/or cyclic operating
conditions
– The procedures in this Part can be used to qualify a
component for continued operation or for re-rating
40
Overview of API/ASME 579-2006
• Part 10: Creep (New)
– Level 1 Assessment - Limitations
+ Component has been constructed to a recognized code or
standard
+ A history of the component can be provided covering both
past and future operating conditions
+ The component has been subject to less than 50 cycles of
operation including startup and shutdown conditions
+ The component does not contain a flaw such as an LTA,
pitting or crack-like flaw
+ Component has not been subject to fire damage or another
overheating event that has resulted in a significant change in
shape such as sagging or bulging, or excessive metal loss
from scaling
+ The material meets or exceeds minimum hardness and
carbon content limitations
41
Overview of API/ASME 579-2006
• Part 10: Creep (New)
– Level 1 Assessment – Calculations: single operating condition
100
250,000 HRS
STRESS, KSI
25,000 HRS
10 2,500 HRS
250 HRS
25 HRS
1
600 700 800 900 1000 1100 1200
TEMPERATURE, F
42
Overview of API/ASME 579-2006
• Part 10: Creep (New)
– Level 1 Assessment – Calculations: multiple operating condition
DAMAGE ISOTHERMS
10.00
750,F
775,F
800,F
Dcj Rcj tsej
825,F
850,F
STRESS, KSI
875,F
900,F
J
Dctotal Dcj 0.25
925,F
950,F
975,F
1000,F
1025,F j 1
1.00
1050,F
1E-08 1E-07 1E-06 1E-05 1E-04 1E-03 1075,F
DAMAGE RATE, FRACTIONAL DAMAGE/HR
43
Overview of API/ASME 579-2006
• Part 10: Creep (New)
– Level 2 Assessment - Limitations
+ Component has been constructed to a recognized code or
standard
+ A history of the component can be provided covering both
past and future operating conditions
+ The component has been subject to less than 50 cycles of
operation including startup and shutdown conditions
+ The component does not contain a flaw such as an LTA,
pitting or crack-like flaw
– Level 2 Assessment - Calculations
+ Analysis (i.e. FEA) used to determine temperature and stress
as a function of time
+ Material data and damage rule used to determine
acceptability for continued operation
+ Method based on MPC Project Omega JIP
44
Overview of API/ASME 579-2006
45
Overview of API/ASME 579-2006
46
Overview of API/ASME 579-2006
47
Overview of API/ASME 579-2006
48
Overview of API/ASME 579-2006
• Appendices – updates previously discussed have been
completed
– Appendix B – Stress Analysis Overview for a FFS Assessment -
Change, complete rewrite to incorporate new elastic-plastic
analysis methods and fatigue evaluation technology developed
for the ASME Div 2 Re-write Project
– Appendix C – Compendium of Stress Intensity Factor Solutions -
Change, new stress intensity factor solutions for thick wall
cylinders, through wall cracks in cylinders and spheres, holes in
plates
– Appendix E - Compendium of Residual Stress Solutions -
Change, complete rewrite to incorporate new solutions
developed by PVRC Joint Industry Project
– Appendix F – Material Properties for a FFS Assessment - Change,
new fracture toughness estimation methods and stress-strain
curve model incorporated
– Appendix H – Technical Basis and Validation of FFS Procedures –
NEW, technical basis document that provides an overview of the
technical background and validation with essential references
– Appendix K – Crack Opening Areas - NEW, appendix covering
crack opening areas for through-wall flaws in cylinders and
spheres
49
Future Enhancements After the 2006
Publication of API/ASME 579
• Technology Development Efforts Currently Underway
– Documentation of validation of new assessment procedures
for HIC/SOHIC damage (2006)
– Allowable Remaining Strength Factor (RSFa) calibration
based on original construction code (2006)
– Assessment of local thin areas (2007)
+ Development of a new method for computing the RSF factor for
both Level 1 and Level 2 Assessments
+ Development of new LTA-to-LTA spacing criteria
+ Development of new LTA-to-structural discontinuities spacing
criteria
+ Development of new rules for assessment of local thin areas at
nozzles and other shell discontinuities
– Completion of Example Problems Manual (2007)
50
Future Enhancements After the 2006
Publication of API/ASME 579
51
Future Enhancements After the 2006
Publication of API/ASME 579
• Future Technology Needs
– Improved fracture toughness evaluation for in-service
materials
+ Carbon steel and low alloys
+ Environmental effects (e.g. hydrogen)
+ Temperature dependency
+ Statistical evaluation
– Improved assessment procedures for dents and dent-
gouge combinations
+ Removal of geometry restrictions
+ Coverage of more materials
+ Coverage of more loading types
– Evaluation of material toughness effects on the burst
pressure of components with non-crack-like flaws (i.e.
LTAs, pitting)
52
Future Enhancements After the 2006
Publication of API/ASME 579
• Future Technology Needs
– Assessment Procedures for Crack-Like Flaws
+ FAD dependency on stress-strain curve
+ Evaluation of pressure test and warm pre-stress effects
+ Improved crack growth models, including data, considering
environmental efforts
– Assessment Procedures for Fatigue
+ Multiaxial fatigue
+ Cycle counting
+ Environmental effects
– Assessment Procedures for Creep Damage
+ Include primary creep in MPC Project Omega Creep Model
+ Creep damage from triaxial stress states
+ Development of new procedures to evaluate creep-fatigue
damage
+ New procedures to evaluate creep-buckling
53
Future Enhancements After the 2006
Publication of API/ASME 579
54
Technical Basis and Validation of
API/ASME 579 FFS Assessment
Methods
• The API CRE FFS and Joint API/ASME Committees are
committed to publishing the technical basis to all FFS
assessment procedures utilized in API 579 in the public
domain
• It is hoped that other FFS standards writing committees
adopt the same policy as it is crucial that FFS knowledge
remains at the forefront of technology on an international
basis to facilitate adoption by jurisdictional authorities
• The new API 579 Appendix H of API 579 provides an
overview of technical basis and validation with related
references organized by damage type, the references are
published in a series of WRC Bulletins and technical papers
55
Technical Basis and Validation of
API/ASME 579 FFS Assessment
Methods
• WRC Bulletins Published
– Review of Existing Fitness-For-Service Criteria for Crack-Like Flaws
(WRC 430)
– Technologies for the Evaluation of Non-Crack-Like Flaws in
Pressurized Components - Erosion/Corrosion, Pitting, Blisters, Shell
Out-of-Roundness, Weld Misalignment, Bulges, and Dents in
Pressurized Components (WRC 465)
– Development of Stress Intensity Factor Solutions for Surface and
Embedded Cracks in API 579 (WRC 471)
– Stress Intensity and Crack Growth Opening Area Solutions for
Through-wall Cracks in Cylinders and Spheres (WRC 478)
– Recent Progress in Analysis of Welding Residual Stresses (WRC 455)
– Recommendations for Determining Residual Stresses in Fitness-For-
Service Assessments (WRC 476)
– Master S-N Curve Method for Fatigue Evaluation of Welded
Components (WRC 474)
56
Technical Basis and Validation of
API/ASME 579 FFS Assessment
Methods
57
Technical Basis and Validation of
API/ASME 579 FFS Assessment
Methods
• WRC Bulletins In Preparation
– An Overview of The Fitness-For-Service Assessment Procedures
for Pitting Damage in API 579
– An Overview of the Fitness-For-Service Assessment Procedures
for Weld Misalignment and Shell Distortions in API 579
– An Overview and Validation of the Fitness-For-Service
Assessment Procedures for Crack-Like Flaws in API 579
– An Overview and Validation of Residual Stress Distributions for
Use in the Assessment Procedures of Crack-Like Flaws in API
579
– An Overview and validation of the Fitness-For-Service Rules for
the Assessment of HIC/SOHIC Damage in API 579
58
Technical Basis and Validation of
API/ASME 579 FFS Assessment
Methods
• WRC Bulletins In Preparation
– MPC Project Omega and Procedures for Assessment of Creep
Damage in API 579
– Development of a Local Strain Criteria Based on the MPC
Universal Stress-Strain Equation
– Update on the Master S-N Curve Method for Fatigue Evaluation
of Welded Components
59
Understanding of Damage
Mechanisms
• The first step in a Fitness-For-Service assessment
performed in accordance with API 579 is to identify the
flaw type and associated damage mechanism
• Appendix G in API 579 provides basic information to assist
the practitioner in this step
• The following WRC Bulletins have been produced to
provide the practitioner with in-depth information
– Damage Mechanisms Affecting Fixed Equipment in the Pulp and
Paper Industry (WRC 488)
– Damage Mechanisms Affecting Fixed Equipment in the Refining
Industry (WRC 489 & API RP 571)
– Damage Mechanisms Affecting Fixed Equipment in the Fossil
Electric Power Industry (WRC 490)
60
In-Service Inspection Codes
and Fitness-For-Service
• Jurisdictional acceptance provided by reference from
in-service inspection codes in the US
– API 510 – Vessels
– API 570 – Piping
– API 653 – Tankage
– ANSI/NB-23 – Vessels & Boilers
• Status of reference from US inspection codes is as
follows:
– API 510 – Reference in 8th Edition, 2nd Addendum
– API 570 – Reference in 2nd Edition, 2nd Addendum
– API 653 – Reference to appear in 3rd Edition, 1st Addendum
– ANSI/NB-23 – Reference in Introduction of 2001 Addendum
• Working to achieve recognition by other international
in-service inspections codes
61
In-Service Inspection Codes
and Fitness-For-Service
• Reactive FFS can be used to assess damage found
during an inspection; provides basis for run, repair, or
replace decision
• Proactive FFS can be used prior to shut-downs to help
develop inspection plans (e.g. determine maximum
permissible flaws sizes)
• The remaining life is determined as part of an FFS
assessment:
– Used to establish an inspection interval
– Half-life or similar concepts can be used
– “Snap-Shot” approach to FFS is not adequate, an evaluation of the
time dependency of damage is required
62
Fitness-For-Service and RBI -
Complimentary Technologies
• Assessment of damage in many of the RBI methods
currently being used is needs updating; is not consistent
with FFS assessment procedures
• Documented and validated FFS methods for flaw and
damage assessment may be used to establish a probability
of failure as a function of time by considering uncertainties
in the damage model and independent variables
• The resulting probably of failure can be combined with a
consequence model to produce an estimate of risk as a
function of time
• Time dependency of risk permits development of an
inspection plan
• Work is underway to integrate API 579 with API 581
63
Harmonizing Pressure Vessel Design and
Fitness-For-Service
64
Summary
• Fitness-For-Service (FFS) assessments are quantitative
engineering evaluations that are performed to demonstrate
the structural integrity of an in-service component containing
a flaw or damage
• API and ASME have agreed to form a joint committee to
produce a single FFS Standard, API/ASME 579, that can be
used for pressure-containing equipment
– Permits focusing of resources in the US to develop a single
document that can be used by all industries
– Helps avoid jurisdictional conflicts and promotes uniform
acceptance of FFS technology
• The 2006 edition of API/ASME 579 represents a significant
update in assessment procedures
• The technical basis and validation of the API/ASME 579 FFS
assessment procedures will be published in the public domain
• API/ASME 579 FFS assessment methods have been integrated
with API & NBIC inspection codes and will be integrated into
API RBI technologies
• Significant technical development work remains and a work
plan is being formulated
65
Robert Brown, P.E.
FFS Team Leader
216-283-6015
rgbrown@equityeng.com
66