Section 8 - Assessment of Metal Loss - General

Fitness-for-Service (FFS) Assessment
based on API RP579

Section 8 - Assessment of Metal Loss -
General
Copyright 2005, TWI Ltd 1
Copyright 2005, TWI Ltd World Centre for Materials Joining Technology World Centre for Materials Joining Technology
Assessment of Metal Loss Assessment of Metal Loss
General General
Introduction Introduction
Some important concepts Some important concepts
General (uniform) metal loss General (uniform) metal loss
Locally thinned areas (LTAs) Locally thinned areas (LTAs)
Pitting metal loss Pitting metal loss
Remediation & remaining life Remediation & remaining life
based on API RP579
General
Remaining strength factor Remaining strength factor
The RSF (remaining strength factor) is an
important concept in metal loss assessments.
RSF =
Plastic collapse load of a
damage component
Plastic collapse load of a
undamaged component
The RSF is not the same as a factor of safety
Allowable RSF Allowable RSF
The RSF
a
(allowable remaining strength factor)
is a function of the allowable stress and design
criteria of the construction code
Lower allowable stresses and conservative
design rules result in a lower RSF
a.
Recommended RSF
a
is 0.9 (for ASME B&PV
pressure equipment in API RP 579)
A RSF
a
0.9 implies that a component containing
a flaw can be no less that 90% of the strength in
the as-built condition
based on API RP579
General
Future Corrosion Allowance Future Corrosion Allowance
FCA = future corrosion allowance FCA = future corrosion allowance
As the name states this variable is the As the name states this variable is the
allowance for further metal loss. This is allowance for further metal loss. This is
usually set by examining inspection usually set by examining inspection
records and determining the metal loss records and determining the metal loss
expected over proposed future life expected over proposed future life
expectancy expectancy
Care should be taken as not all corrosion Care should be taken as not all corrosion
rates are linear rates are linear
Thickness information Thickness information
Generally two different thickness Generally two different thickness
measurement results: measurement results:
Point readings, manual ultrasonics with a Point readings, manual ultrasonics with a
matrix of points matrix of points
Detailed manual or auto/scanned Detailed manual or auto/scanned
ultrasonics ultrasonics
based on API RP579
General
Metal loss assessment Metal loss assessment
Most assessment procedures Most assessment procedures
assume smooth metal loss assume smooth metal loss
Most assessment procedures are vague Most assessment procedures are vague
or do not cover metal loss at welds or do not cover metal loss at welds
Lack of side wall fusion
May have been safe as an
embedded flaw.
If metal loss exposes it to
the surface:
Now a surface breaking
flaw
Stress at crack now higher
due to reduction in area
based on API RP579
General
Thus, level 1 and 2 procedures have the Thus, level 1 and 2 procedures have the
following applicability: following applicability:
Equipment is designed and constructed Equipment is designed and constructed
to a recognised standard to a recognised standard
No creep, fatigue or crack No creep, fatigue or crack- -like flaws like flaws
Metal loss has smooth contours Metal loss has smooth contours
Closed Closed- -form design equation which form design equation which
relates pressure to thickness relates pressure to thickness
General (Uniform) Metal Loss General (Uniform) Metal Loss
based on API RP579
General
General metal loss General metal loss
The general metal loss procedure is in API The general metal loss procedure is in API
579 Section 4 579 Section 4
The procedure is based on a thickness The procedure is based on a thickness
averaging approach with code rules to averaging approach with code rules to
determine acceptability determine acceptability
The code rules are for ASME and API The code rules are for ASME and API
equipment equipment
For the thickness readings the coefficient For the thickness readings the coefficient
of variation is calculated (COV) of variation is calculated (COV)
A
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e

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s
A
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t
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s
s
Standard deviation Standard deviation
COV = COV =
Standard deviation Standard deviation
Average thickness Average thickness
Frequency Frequency
D
e
p
t
h

o
f

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a
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i
n
g
D
e
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o
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a
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i
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g
based on API RP579
General
If the COV is less than 10% then it is classed as If the COV is less than 10% then it is classed as
uniform metal loss, else its non uniform metal loss, else its non- -uniform loss and uniform loss and
the thickness averaging approach (section 4) or the thickness averaging approach (section 4) or
section 5 local metal loss or a level 3 analysis section 5 local metal loss or a level 3 analysis
should be used. should be used.
level 1 assessment: level 1 assessment:
If minimum required thickness (t If minimum required thickness (t
min min
) to code ) to code
calculation is less than or equal to average calculation is less than or equal to average
thickness (t thickness (t
am am
) minus the FCA then the metal loss ) minus the FCA then the metal loss
is acceptable is acceptable
Level 2 assessment: Level 2 assessment:
Similar to level 1 except t Similar to level 1 except t
min min
is adjusted is adjusted
by using the by using the RSF RSF
a a
(0.9) (0.9)
Limits of applicability: Limits of applicability:
0.5t 0.5t
min min
or 0.1 inches (2.5mm) or 0.1 inches (2.5mm)
Not close to a structural discontinuity Not close to a structural discontinuity
based on API RP579
General
Level 3 assessment: Level 3 assessment:
Finite element analysis either elastic or Finite element analysis either elastic or
elastic elastic- -plastic plastic
No limitations e.g. can include fatigue No limitations e.g. can include fatigue
General metal loss - example General metal loss - example
Corrosion on a cylindrical section of pressure Corrosion on a cylindrical section of pressure
vessel has been found during an inspection. vessel has been found during an inspection.
The vessel was designed and constructed to The vessel was designed and constructed to
the ASME B&P VIII division I. Evaluate if the the ASME B&P VIII division I. Evaluate if the
vessel is fit vessel is fit- -for for- -service. service.
Design Conditions = 300 psig @ 350 Design Conditions = 300 psig @ 350
o o
F F
Inside Diameter = 48 inches Inside Diameter = 48 inches
Nominal Thickness = 0.75 inches Nominal Thickness = 0.75 inches
Future Corrosion Allowance = 0.10 inches Future Corrosion Allowance = 0.10 inches
Material = SA 516 Grade 70 (S = 17500 psi @ Material = SA 516 Grade 70 (S = 17500 psi @
temperature) temperature)
Weld Joint Efficiency = 0.85 Weld Joint Efficiency = 0.85
based on API RP579
General
General metal loss - example General metal loss - example
Units in inches standard deviation is 0.0144
O'clock
0 10 20 30 40 50 60 70
0 0.559 0.555 0.576 0.551 0.552 0.547 0.552 0.578
1.5 0.589 0.584 0.560 0.581 0.549 0.545 0.551 0.574
3 0.568 0.547 0.568 0.573 0.582 0.564 0.555 0.547
4.5 0.570 0.586 0.583 0.580 0.560 0.587 0.547 0.548
6 0.586 0.584 0.561 0.572 0.562 0.567 0.590 0.569
7.5 0.591 0.558 0.554 0.579 0.577 0.570 0.546 0.587
9 0.547 0.590 0.555 0.583 0.566 0.570 0.555 0.565
10.5 0.570 0.560 0.555 0.562 0.570 0.568 0.547 0.587
Distance along shell in inches

Section 8 - Assessment of Metal Loss - General

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Fitness-for-Service (FFS) Assessment

based on API RP579

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