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Presentation Overview
Introduction
Study Goals
FFS Software Algorithm
FFS Software Interfaces
FFS Case Studies
Conclusions and Recommendations
Introduction to FFS
3
Definition of FFS
4
Inspection
or
NDE
Engineers
Run,
repair or replace decisions
Information
Information
Presentation Overview
Introduction
Study Goals
FFS Software Algorithm
FFS Software interface
FFS Pilot Studies
Conclusions and Recommendations
Study goals
6
Developing a Fitness-For-Service
software package
Implementation of FFS
Recommendations for improving upon
existing methodologies
Petroleum University of Technology
Presentation Overview
Introduction
Study Goals
FFS Software Algorithm
FFS Software Interfaces
FFS Pilot Studies
Conclusions and Recommendations
Part 1,2:
Introduction
Part 3: Brittle
Fracture
Part 4: General Metal
Loss
Part 5: Local Metal Loss
Part 6: Pitting Corrosion
Part 7: Hydrogen Blisters and Hydrogen
Damage
Part 8: Misalignment and Shell
Distortions
Part 9: Crack-Like
Flaws
Part 10:
Creep
Part 11: Fire
Damage
Part 12: Dents, Gouges,
and
Dent-Gouge
Combinations
Part 13: Lamination
Assessment Levels
10
Level 1
Assess
ment
Levels
Level 2
Level 3
Screening
Low complexity
High
conservatism
Medium detail
Medium
complexity
Medium
conservatism
Detailed
Most complex
Least
conservative
Petroleum University of Technology
11
Rerating is recommended
MAWP
MAWP
(RSF/RSF
r =as
a)
Not the
same
Factor
of Safety
Allowable RSF (RSFa) is 0.9
12
13
Limitations:
14
COV PTRs
= tSD
COV10%,
is /t
sufficient
avg
tSD=(S/N-1)0.5
S=(trd,i-tavg)2
N
i=1
OV>10%, Thickness
Profile is require
15
tam - FCA
RSF
t(tmin
a
0.
FCA)
max
0.6
mm
5
[
tmin ,tlim]
(tlim = max [0.2tnom ,2.5mm
(0.10 in)]
16
C1
C2
C3
mm
C4
C6
C5
L ta
tm s
C7
ta
m
tmm
L
tL
a
m
ta
m
R
Remaining
Thickness
D:t: Inside
Diameter
tRatio
c: tnom-LOSS-FCA
Petroleum University of Technology
17
s
c
s
tmin
FCA
[t
,
t
am
am
am ] - FCA
RSF
RSF
cC
tmin
t
a
a
FCA
am min
RSFa
tminL
18
19
Thickness profile
Component specifications
MRT
Flaw
Dimensions
MAWP to the nearest
Distance
Weld Joint Efficiency,
structural discontinuity (Lmsd)
A
flaw
Inspection recommendation
Lmsd = min [L1msd, L2msd,
L3msd, ]
Petroleum University of Technology
20
criteria
Longitudinal flaw length parameter
Tru
RSF should beeTrucalculated
e
Tru
e
Thickness to
be used
the assessment
Additional
criterion
forinGroovelike flaws:
Tru
e
Petroleum University of Technology
21
YES
ACCEPTABLE
Mt :
NO
22
e
Tensile
Stress
Tru
level(TSF)
of
Factor
should
e Higher
Truassessment is
be calculated
e
Tru required
e
Tru
e
23
tc
1
A
tm
Increasing
thickness
t2
Increment
t3
24
RSF
s
1
s
2
Increment
tc
21
A
A
Level
2
RSF
s
1
s
2
s
3
Increment
tc
31
A
A
26
RSF
s
1
s
2
s s
3
4
Increment
tc
41
A
A
27
RSF
s
1
s
2
s s
3
s
5
Increment
tc
51
A
A
28
RSF
s
1
s
s
2
s s
3
min
1
RSF
Increment
tc
61
A
A
29
RSFLTA
RSFa
YES
ACCEPTABLE
NO
30
Wight
+ Thermal
Effects of temperature
Support displacements
Petroleum University of Technology
31
tmm
Metal Loss
B
yLX
Df/2
x
D/2
Flaw
inside:
Flaw
Do/2
outside:
tc
Petroleum University of Technology
32
Longitudinal
membrane stree
Hoop stress
Petroleum University of Technology
33
ACCEPTABLE
NO
Circumferential extent of
the flaw is not acceptable
For the weight case, Hf = 1.0
For the weight plus thermal case, Hf =
3.0
S : Allowable stress
34
Pitting Corrosion
Assessment
s
Cylindrical
Shell
35
Pitting Corrosion
Assessment
Level
Utilizes Standard Pit Charts
1
0.8
0.6
0.4
0.2
Cylinder
Sphere
0.88
0.77
0.65
0.53
0.87
0.74
0.60
0.47
6in
Rwt: Remaining
wall thickness
UNACCEPTABLE
ratio
6in
6in
6in
36
Pitting Corrosion
Assessment
Level
1
RSF
RSFa
YES
ACCEPTABLE
NO
Higher level of
assessment is required
Petroleum University of Technology
37
Pitting Corrosion
Assessment
Level
Utilizes Pit-Couples (10 Pit-Couples is
2
required)1
Pit 1
3
Pit 2
Pk
A
2
38
Pitting Corrosion
Assessment
Level
Utilizes Pit-Couples (10 Pit-Couples is
2
required)
d
d
RSF is calculated for each of 10 PitCouples
w
w
i,k
j,k
j,k
i,k
tc
Pk
davg,k =0.5(di,k+
dj,k)
39
Pitting Corrosion
Assessment
LTA
in widelyscattered
scattered
pitting &
Level Widely
Localized
pitting
Pitting confined in LTA
Damage is evaluated as an equivalent
2,
pitting
LTA
tRSF
RSF
pit
= pit
RSF
mm =
comb
tc RSFlta
RSFcomb
RSF
pit
RSFaa
RSF
YES
ACCEPTABLE
s
c
A
RSFpit . tc
NO
Cylindrical
Shell
ttcc
40
Presentation Overview
Introduction
Study Goals
FFS Software Algorithm
FFS Software Interfaces
FFS Case Studies
Conclusions and Recommendations
42
43
45
COV
10%
COV >
10%
Ls
tams
Calculates
Checks
all text
COV
Checks
table
Calculates
boxes
tam L thelength
acceptance
forc thickness
criteria,
creates
averaging,
L
the
report
Petroleum
University of Technology
46
47
48
For non-spherical
sections
CTPcir
Limiting
flaw
Checks
Calculates
Level
all text
Lssiz
criteria
are
boxes
1
2
checked
CTPlong
Petroleum University of Technology
49
If
Evaluate the
supplementa
results and
lprepare
loads are
the
present
report
Petroleum University of Technology
50
51
Level
1
Checks
Calculates
all text
boxes
acceptance
Rwt
criteria, creates
the report
Petroleum University of Technology
52
Level
2
Checks
Calculates
all
text
RSF
Evaluates
the
boxes
for damaged
10and
Pitresults
area
Couples
creates
the
report
Petroleum University of Technology
53
Presentation Overview
Introduction
Study Goals
FFS Software Algorithm
FFS Software Interfaces
FFS Case Studies
Conclusions and Recommendations
Corresponding
values
Design code
Uniform
metal loss (LOSS)
ASMEinB31.3
0.08
Future Corrosion
Material
specification
Allowance
(FCA)
Design condition
API 5L
0.06
inGrade B
C1
C2
C3
C4
C5
C6
C7
C8
C9
M1
0.23
0.23
0.22
0.22
0.22
0.21
0.22
0.23
0.22
0.23
0.23
0.23
0.21
M2
0.23
0.22
0.21
0.20
0.21
0.20
0.21
0.21
0.22
0.22
0.23
0.23
0.21
M3
0.23
0.21
0.19
0.18
0.20
0.17
0.17
0.20
0.20
0.22
0.22
0.23
0.17
M4
0.21
0.20
0.18
0.18
0.18
0.16
0.17
0.19
0.20
0.21
0.21
0.22
0.16
M5
0.21
0.20
0.19
0.17
0.18
0.16
0.16
0.17
0.19
0.19
0.20
0.23
0.16
M6
0.21
0.20
0.20
0.20
0.19
0.17
0.18
0.18
0.21
0.19
0.20
0.23
0.17
M7
0.22
0.21
0.21
0.20
0.21
0.19
0.20
0.21
0.22
0.22
0.21
0.22
0.19
M8
CTP
0.23
0.23
0.22
0.21
0.22
0.21
0.23
0.22
0.23
0.23
0.22
0.23
0.21
0.21
0.20
0.18
0.17
0.18
0.16
0.16
0.17
0.19
0.19
0.20
0.22
Thickness
min RSF8 to be used in the assessment (tc)
0.235
0.836 inches
0.235
inches
0.838
Remaining
min RSF9 thickness ratio (Rt)
0.426
0.805
0.426
0.805
Longitudinal
flaw length parameter ()
min RSF10
8.8
0.823
8.8
0.825
min
RSF111
min RSF
0.806
0.812
0.808
0.814
2
min
RSF RSF
0.804
0.804
0.805
0.805
min
min
RSF3 extent of the flaw status
Longitudinal
0.814
Unacceptable
min
RSF4
Circumferential extent of the flaw status
Unacceptable
0.816
Unacceptable
0.828
0.830
Unacceptable
min RSF5
min RSF6
for continued
operation
0.815
Final result
min RSF7
0.840
0.843
Petroleum University of Technology
Load
F (N)
My (N.m) YesV (N)
Supplemental
loads Mx (N.m)12 mm
Nominal wall
thicknesses
cases
(tnom)
Weight
2224
20.224104
0.00
609406
18.417103
Thermal
29.263103
Minimum measured
thickness (t )
1066 mm
43.047104
5 mm
0.00
170812
MT (N.m)
M1
9.65
9.65
9.40
9.40
9.65
9.40
9.40
8.65
8.90
9.14
9.40
9.65
8.65
M2
9.65
9.65
9.65
8.90
8.40
8.40
8.90
8.14
8.90
9.14
9.40
9.65
8.14
M3
9.65
9.40
9.65
7.60
7.90
6.90
6.35
7.90
6.90
7.10
8.14
9.14
6.35
M4
9.65
9.65
9.65
6.60
6.35
5.10
6.35
6.10
6.60
6.35
7.60
9.14
5.10
M5
9.65
9.40
8.14
7.10
6.90
5.60
5.10
5.60
6.60
6.35
7.10
9.40
5.10
M6
9.65
9.65
8.14
6.10
6.35
6.60
5.10
6.35
6.60
6.60
6.35
9.14
5.10
M7
9.65
9.65
7.90
6.10
7.40
7.10
5.85
6.35
7.10
6.60
6.10
9.14
5.85
M8
CTP
9.65
9.65
8.90
8.90
8.65
8.40
7.40
7.10
7.90
7.90
8.40
9.14
7.10
9.65
9.40
7.90
6.10
6.35
5.10
5.10
5.60
6.60
6.35
6.10
9.14
lmB (MPa)
(MPa)
eA (MPa)
eB (MPa)
Weight
409.17
404.62
17.85
376.37
371.91
719.62
707.14
27.84
684.20
671.81
Load cases
min
RSF10 membrane
Longitudinal
flaw length
parameter
Longitudinal
stress
at point()
A (lmA)
Load cases
0.769
0.807
10
mm
10
mm
Weight +
Weight +
0.807
0.804
Weight 0.370
Weight 0.370
Thermal
Thermal
0.770
0.760
409.17 MPa 5.15
719.62 MPa 421.33 MPa5.15
724.50 MPa
11 1
min
minRSF
RSF
Longitudinal
membrane stress at point B (lmB)
404.62 MPa
min
RSF8 to be used in the assessment (tc)
Thickness
min
RSF9 thickness ratio (Rt)
Remaining
0.780
0.590
707.14 MPa
0.773
0.588
410.71 MPa 711.14 MPa
RSF
minminRSF2
0.751
0.590
Shear stress ()
17.85 MPa
27.84 MPa
3
min RSFat
0.729
Diameter
the base of the region of metal loss (Df)
1085
mm
Longitudinal extent of the flaw status
Unacceptable
Circumferential
angular extent of the region of
min RSF4
0.780
0.234 radians
Circumferential
extent
of
the
flaw
status
Unacceptable
metal loss 5()
min RSF
0.811
Final
The vessel is not
acceptable
RSF result
0.774
0.748
0.588
17.92 MPa
27.91 MPa
0.728
1085
mm
Unacceptable
0.781
0.234 radians
Unacceptable
0.809
The component
0.770is not fit
0.805
for continued
operation
1474.7 kPa
0.781
81.7 MPa
circumferential
6
min RSF
for continued 0.805
operation.
MAWPr
1482.4 kPa
min RSF7
0.783
Circumferential stress resulting from pressure (cm)
81.6 MPa
63
Presentation Overview
Introduction
Study Goals
FFS Software Algorithm
FFS Software Interfaces
FFS Pilot Studies
Conclusions and Recommendations
Conclusions
64
Conclusions
65
66
Recommendations for
future study
MAWPr
f K mat MAWP
RSFa
List of publications
67
:
-4 :
978964880685
A. Amiri Yekta, S. Javadpour, M.H. Maddahi, A detailed study on FitnessFor-Service assessment for localized corrosion in fluid catalytic cracking
unit pressure vessel, submitted to International Journal of Pressure
Vessel and Piping.