API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

ABC-1234
Vessel

A Plant
Equipment:
Date:

LP Separator
5th September 2014

Introduction
The following Level 2, Fitness-For-Service assessment was carried out on A Plant Production Platf
1234, LP Separator, Nozzle: N-01, in accordance with API 579-1, Part 5, for Type 'B' pressurized c
subject to local metal loss resulting from internal corrosion, using the methods outlined in API 57

A region of local internal corrosion was found in the NPS-14, Schedule 140 nozzle during inspecti
pressure vessel (see inspection data).
The vessel was constructed to the ASME B&PV Code, Section VIII, Division 1, 1988 edition and is
fatigue service.

A Level 2 assessement was performed because the corrosion is at a major structural disconitnuit
nozzle.

The assessement was performed, to determine if the vessel is acceptable for continued operatio
Limit Analysis Method. This method is effective for evaluating a region of local metal loss at nozz
average thickness is used to represent the metal loss in the nozzle reinvorcement zone (see Figu
A.7).

The zone for thickness averaging has been calculated in accordance with API 579-1, Part 4, parag
details of which can be found in Appendix 1 of this report.
Summary
The area reinforcement calculation using the limit analysis approach is acceptable based on the
corroded dimension of the nozzle configuration and the stated design conditions.
The Level 2 Assessment criteria are satisfied.
The vessel is acceptable for continued operation.

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

ABC-1234
Vessel

A Plant
Equipment:
Date:

LP Separator
5th September 2014

Nomenclature
cn

LOSSn + FCAn.

cs

LOSSs + FCAs.

d1

nozzle diameter (for required spacing between two openings calculation).

d2

nozzle diameter of nearest opening.

di

current inside diameter of the nozzle including the specified FCA.

dm

nozzle or branch pipe mean diameter corrected for LOSS and FCA as applicable.

do

outside diameter of the nozzle corrected for LOSS and FCA as applicable.

D
Di

inside shell diameter corrected for LOSS and FCA as applicable.

Do

outside diameter corrected for LOSS and FCA as applicable.

Dm

vessel or run pipe mean diameter corrected for LOSS and FCA as applicable.

nominal inside shell diameter, not corrected for LOSS and FCA.

FCAn nozzle future corrosion allowance.

FCAs shell future corrosion allowance.
L
Ln

axial length of nozzle with thickness tn .

dimension to define the height of the reinforcement zone (see Figure 4.9).

Lv

dimension to define the width of the reinforcement zone (see Figure 4.9).
LOSSn metal loss in the nozzle from prior periods of operation equal to the nominal (or furnished

available) minus the minimum measured thickness at the time of the inspection.
LOSSs metal loss in the shell from prior periods of operation equal to the nominal (or furnished th
available) minus the minimum measured thickness at the time of the inspection.

nozzle calculation parameter.

P
Rs

internal design pressure.

Sn

allowable stress for the nozzle.

Sv

allowable stress for the vessel.

nozzle
tam
shell
tam

the average nozzle thickness in the nozzle reinforcement zone.

inside radius of small cylinder at a conical transition corrected for LOSS and FCA as applica

the average shell thickness in the nozzle reinforcement zone.

t
te

shell thickness.

tr

required thickness of the vessel wall computed with E = 1.0.

tn

furnished nozzle wall thickness (see Figures A.6 and A.7) For an integrally reinforced noz

tp

furnished wall thickness of the pipe section for an integrally reinforced nozzle (see Figure A.7).

tv

furnished vessel thickness.

tstd

nominal thickness of ANSI B36.10 standard weight pipe.

nominal thickness of the reinforcing pad = 0.00. (See Appendix 2 formulas).

UTS

ultimate tensile strength.

YS

yield stress.

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

ABC-1234
Vessel

A Plant
Equipment:
Date:

LP Separator
5th September 2014
Notes

Vessel Shell Design Data

Material
Allowable Stress (Sv)
Design Conditions (P)
Inside Diameter (Di)
Max. Design Temperature
Inside Diameter (Do)
Inside Radius (Rs)
Nominal Thickness (t) (tv)
Corrosion Allowance (FCAs)
Metal Loss (LOSSs)
Weld Joint Efficiency (E)
Cylindrical Vessel

SA-516, Grade 70, year 1988

17500
psi
185
psig @350 F
60.000
in
350
F
60.250
in
30.000
in
0.600
in
0.125
in
0.000
in
1.0
YES

Nozzle Design Data

Material
Ferrous material
Allowable Stress (Sn)

SA-106, year 1988

YES
17500
psi
Design Conditions (P)
185
psig
Minimum Specified Yield Strength (YS)
38000
psi
Min. Specified Ultimate Tensile Strength (UTS)70000
psi
Max. Design Temperature
350
F
Temp. limit (API 579-2, Table A.2)
800
F
Nominal Pipe Size (NPS)
14
in
Inside Diameter (Do) (d1) (di)
14.000
in
Nominal Thickness (tn) or (tp)
1.250
in
Corrosion Allowance (FCAn)
0.125
in
Metal Loss (LOSSn)
0.000
in
Axial Length of Nozzle with Thickness tn (L)
5.000
in
Weld Joint Efficiency (E)
1.0
Nozzle Loads
0.0
Thickness Re-pad (te)
0.000
in
Distance to Nearest Structural Discontinuity 45.00
in
OD of Nearest Major Structural Discot. (d2)
12.75
in
Is the Opening Circular
YES
Is Nozzle Normal to the Surface of the Vessel YES
Is the Vessel Cylindrical
YES

YES or NO

Figures A.6 and A.

Negligible

Nom. Tkns ANSI B36.10 Std. Weight Pipe (tstd)

0.375

in

See Limitations (x

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

Inspection Data
A sketch of the nozzle and metal loss are shown below.
CL
1.25"

0.375"

Metal Loss

0.60"
The average nozzle thickness in the nozzle reinforcement
zone is 0.875 in.
The corrosion is uniform for all inspection planes.

A Level 2 assessment is performed as per API 579-1 paragragh 5.4.3.5 because the corrosion is a
discontinuity (a nozzle). The assessment procedure in Part 4, paragraph 4.4.3.3. is used.
From the inspection data:
0.875 in
nozzle
tam

0.600 in

tshell

am
Required
thickness of shell:

tr

P(Rs LOSSs FCAs)

SvE 0.6P

0.320 in

Determine the corroded shell and nozzle mean diameters:

61.200 in

Do Di 2t

60.250 in

D Di 2(LOSSs FCSs)

60.725 in

Dm

Do D
2

API 579-1 R

Dm

Do D
2

14.000 in

do

12.500 in

d do 2t

nozzle
am

dm

do d
2

2FCAn

13.250 in

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

The following assessment is performed using the limit analysis method:

(See API 579-1, Annex A, A.3.11.b).
Limitations
(i)

Temperature Limits; API 579-1, Table A.2.

Maximum Design Temp =
Temperature Limit =

(ii)

350 F
800 F

Are the temperature limits satisfied:

YES

Are the nozzle and shell fabricated from ferrous material:

YES

With, YS = minimum specified yield strength, and UTS = minimum specified ultimate tens
YS =
UTS =

38000 psi
70000 psi

Is YS/UTS < 0.80:

YES

(iii)

Does the opening not exceed NPS 24:

YES

(iv)

with

0.2182

dm
Dm

if

dm
Dm

or if

dm
Dm

and

t
then

0.5

Dm
t

then

0.5

Dm

Dm
t

101.2083

FALSE

100
TRUE

250

Do either of the parameters meet the above requirements:

YES

(v)

The opening is not subject to cyclic loading:

YES

(vi)

The opening is in a cylindrical vessel:

YES

with

cn LOSSn FCAn

0.125 in

Is the opening located at a distance of

1.8 Dm(t cs)

from any major structural discontinuities:
Distance

YES

9.6673 in

1.8 Dm(t cs)

Distance to nearest structural disconinuity = 45.00 in

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:
(vii)

(ix)

d1 =
d2 =

14.000 in
12.75 in

Required spacing =

40.125 in

d d
3 1 2
2
Does the spacing meet minimum
requirements:

YES

Is the opening circular:

YES

Is vessel cylindrical:

YES

Is nozzle normal to the surface of the cylindrical vessel:

YES

If L <
L=

nozzle
0.5 dmtam

nozzle
m am

0.5 d t
Is L <

then use tn = tp in equations (A.110) and (A.111) below.

5.00 in
1.7025 in

NO

nozzle
0.5 dmtam

tn (or tp) =
(x)

LP Separator
5th September 2014

The spacing between two openings:

with
and

(viii)

ABC-1234
Vessel

A Plant
Equipment:
Date:

1.250 in

Is tn > 0.875std through an axial length of L <

nozzle
tam

0.875 tstd =

0.875 in

nozzle
0.5 dmtam

0.3281 in

Is tn > 0.875std
through an axial length of :

YES

1.7025 in

nozzle
0.5 dmtam

(xi)

YES

Are nozzle loads significant:

NO

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

ABC-1234
Vessel

A Plant
Equipment:
Date:

LP Separator
5th September 2014

Assessment Procedure

API 597-1

with,

cn LOSSn FCAn
nozzle
tam
cn

shell
tam
cs

0.750 in
0.475 in

shell
tam
cs
nozzle
tam
cn

0.125 in

1.579 in

The following two equations must be satisfied:

3/2

1/2

tnozzle c
d
n
am
2 2 m

shall

1.25
t shell c
D
t

c
m
am
s
s
am

2.95
3/2

1/2
tr
d tnozzle c

am
n

1 m
nozzle

Dm tam cs

nozzle

A tam cn 228

tnozzle c

am
s

2
108 228

where,

d
m

Dm

Dm t cs

(A.110)

nozzle
tam
cn dm

B 155

shell

D
tam cs m

0.93 0.005
2

dm

228 152

Dm

tr

shell

c
am
s

(A.111)

 d
m

Dm

Dm t cs

(A.112)

A = 162

nozzle
tam
cn

for

shall
am

t
B = 210

nozzle
tam
cn

for

shall
am

shall
am

t
B = 318

cs

nozzle
tam
cn

for

A = 54

cs

cs

nozzle
tam
cn

for

shall
am

cs

(A.113)

1.0

(A.114)

1.0

(A.115)

1.0

(A.116)

1.0

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

with
nozzle
tam
cn
shell
tam
cs

1.579 in

A=

54

B=

318

d
m

Dm

t c
D
m
s

3/2

d
2 2 m

Dm

tnozzle c
am
n

2.4671 in

1/2

t shall c 1.25
am
s

3/2
1/2
nozzle

dm
t
cn
am

nozzle

Dm tam cs

t shell c
s
2.95 am

2.7715

4.3721

Is equation (A.110) satisfied:

nozzle

nozzle

A tam cn 228 tam cn dm B 155

t shell c D
tnozzle c
am
m
s
s
am

1.0478

d
2
m

108 228
228 152

Dm

YES

 nozzle

nozzle

A tam cn 228 tam cn dm B 155

t shell c D
tnozzle c
am
m
s
s
am

d
108 2 228 m
228 152

Dm

0.93 0.005 shell r

tam cs

0.6358

Is equation (A.111) satisfied:

YES

Analysis Results
The area reinforcement calculation using the limit analysis approach is acceptable based on the
dimension of the nozzle configuration and the stated design conditions.
The Level 2 Assessment criteria are satisfied.
The vessel is acceptable for continued operation.
API 579-1 Fitness-For Service Assessment
Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

Figure A.6, Nozzle Parameters - Limit Load Analysis

CL

dm
Nozzle

Reinforcement
Zone

tr
n

tn

Vessel

tr

Ln

Metal Loss

Dm
Lv

Lv

Nozzle Without Reinforcing Element

Figure A.7, Nozzle Parameters (Integrally Reinforced Nozzle Neck) - Limit Load Ana
CL

dm
tr
n

tr
n

tp
Nozzle

Reinforcement
Zone
tn

L
Vessel

Ln

tr

Metal
Loss

Ln

Dm

Lv

Lv
Integrally Reinforced Nozzle

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

Appendix 2

Figure 4.9, Zone for Thickness Averaging - Nozzles and Fabricated Branch Connect
CL
Reinforciment
Zone

Nozzle

Reinforcing Pad

tn
Ln

te

di

tv

Lni

Lv

with
di =

14.000 in

Lv

Shell

tn =
tv =
te =

1.250 in
0.600 in
0.000 in

Lv = max [di, (di/2 + tn + tv)], thickness averaging zone in the horizontal direction.
Lno = min [2.5tv, (2.5tn + te)], thickness averaging zone in the vertical direction.

Lni = min [2.5tv, 2.5tn], thickness averaging zone in the vertical direction on the inside of the she
Lv =
Lno =
Lni =

14.0 in
1.5 in
1.5 in

Page 1
A Plant
5th September 2014

sment was carried out on A Plant Production Platform, ABCe with API 579-1, Part 5, for Type 'B' pressurized components
al corrosion, using the methods outlined in API 579-2, 5.6.

n the NPS-14, Schedule 140 nozzle during inspection of the

Code, Section VIII, Division 1, 1988 edition and is not in the

the corrosion is at a major structural disconitnuity, that is, at a

if the vessel is acceptable for continued operation, using the

for evaluating a region of local metal loss at nozzles where the
al loss in the nozzle reinvorcement zone (see Figures A.6 and

culated in accordance with API 579-1, Part 4, paragraph 4.3.3.4,

this report.

mit analysis approach is acceptable based on the

and the stated design conditions.

Page 2
A Plant
5th September 2014

ds of operation equal to the nominal (or furnished thickness if

of operation equal to the nominal (or furnished thickness if

al transition corrected for LOSS and FCA as applicable.

res A.6 and A.7) For an integrally reinforced nozzle (see Figure A.7),

or an integrally reinforced nozzle (see Figure A.7).

Page 3
A Plant
5th September 2014

Figures A.6 and A.7

See Limitations (x), below

Page 4
A Plant
5th September 2014

79-1 paragragh 5.4.3.5 because the corrosion is at a major structural

API 579-1 REFERENCE?

Page 5
A Plant
5th September 2014

ngth, and UTS = minimum specified ultimate tensile strength.

Page 6
A Plant
5th September 2014

Page 7
A Plant
5th September 2014
API 597-1 Reference

(A.110)

(A.111)

(A.112)

(A.113)

(A.114)

(A.115)

(A.116)

Page 8
A Plant
5th September 2014

mit analysis approach is acceptable based on the corroded

stated design conditions.

fied.

eration.
Page 9
A Plant
5th September 2014

rameters - Limit Load Analysis

lly Reinforced Nozzle Neck) - Limit Load Analysis

Page 10
A Plant
5th September 2014

Appendix 2

ng - Nozzles and Fabricated Branch Connections

ne in the vertical direction on the inside of the shell.