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Prepared by Ray Delaforce For Internal Use Only

1. A pressure vessel inspection found an area of corrosion that requires further analysis to determine if the vessel can continue operating at its current pressure rating. 2. Measurements of the corroded area were taken and the minimum thickness was found to be 0.36 inches. 3. Based on a Level 1 assessment, the maximum allowable working pressure is derated from the design pressure of 300 psi down to 207 psi. A more detailed Level 2 assessment may be performed.

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Edwin Mariaca
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© © All Rights Reserved
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90 views

Prepared by Ray Delaforce For Internal Use Only

1. A pressure vessel inspection found an area of corrosion that requires further analysis to determine if the vessel can continue operating at its current pressure rating. 2. Measurements of the corroded area were taken and the minimum thickness was found to be 0.36 inches. 3. Based on a Level 1 assessment, the maximum allowable working pressure is derated from the design pressure of 300 psi down to 207 psi. A more detailed Level 2 assessment may be performed.

Uploaded by

Edwin Mariaca
Copyright
© © All Rights Reserved
Available Formats
Download as PPS, PDF, TXT or read online on Scribd
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Prepared by Ray Delaforce for internal use only

API 579 Example 4.11

Pressure Vessel Information:

Design Conditions = 300 psig @ 350 OF

Inside (new) Diameter = 48 inches D

Nominal Thickness = 0.75 inches

Uniform Metal Loss = 0 inches (no general corrosion)

Future Corrosion Allowance = 0.10 inches FCA

Material = SA 516 Grade 70

Joint Efficiency = 0.85


PERFORM THE INITIAL CALCULATIONS

CALCULATE THE MINIMUM REQUIRED THICKNESS:

Using the ASME VIII, Division 1 Code


In the Circumferential (hoop) Direction
P x ( R + FCA )
tCmin =
SE 0.60 x P
300 x ( 24 + 0.10 )
= = 0.492 inches
17500 x 0.85 0.60 x 300

In the Longitudinal ( axial ) Direction


P x ( R + FCA )
tLmin =
2SE + 0.40 x P

300 x ( 24 + 0.10 )
= = 0.242 inches
2 x 17500 x 0.85 + 0.40 x 300

tmin = Max ( tCmin, tLmin) = 0.492 inches


WE NOW KNOW THE REQUIRED MINIMUM THICKNESS

This thickness which is tmin = 0.492 inches

WE MUST NOW CONSIDER THE ACTUAL CURRENT CONDITION OF THE


VESSEL WALL TO ASSESS ITS FUTURE USE

DURING A ROUTINE INSPECTION, AN AREA OF CORROSION IS FOUND


WHAT DO WE DO NOW ?

1 WE DETERMINE THE AREA OF THIS CORROSION

2 WE MEASURE THE VARIOUS THICKNESSES IN THIS AREA

3 LET US NOW SEE HOW WE DO THIS


SURVEY METHOD
1 Find the corrosion area Identify it
2 Overlay a Grid with nodes at the intersections 1.5 inches pitch
3 Label the grid Circumferential and Longitudinal Gridlines
4 Measure thicknesses at every NODE tabulate the results

C1 C2 C3 C4 C5 C6 C7 C8

M1

M2

M3

M4

M5

M6

M7
NOW TABULATE THE VALUES
1 Set out the table of node thicknesses
2 Find the CTP for the Circumference Thicknesses

3 Find the CTP for the Longitudinal Thicknesses


4 Complete the CTP values
5 Determine minimum thickness tmm = 0.36 inches

0.75
0.48
0.55

0.36
0.48
049
0.75

0.75 0.48 0.47 0.55 0.36 0.48 0.49 0.75


WE NOW HAVE THE COMPLETED CTP TABLE

0.75
0.48
0.55

0.36
0.48
049
0.75

0.75 0.48 0.47 0.55 0.36 0.48 0.49 0.75

Minimum measured thickness tmm = 0.36


CONTINUE WITH THE CALCULATION

Find the Remaining Thickness Ratio (Rt):

Rt = tmm - FCA = 0.36 - 0.10 = 0.528


tmin 0.492
Allowable Remaining Strength Factor (RSFa):

Section 2.4.2.2(d) states: Recommended value for


RSFa is 0.90 which is conservative..

RSFa = 0,90
CONTINUE WITH THE CALCULATION

Remaing Thickness Ratio Rt = 0.528


Allowable Remaining Strength Factor RSFa = 0,90
Calculate the Q factor (or read from Table 4.4):

1 - Rt
Q = 1.123 [ (1 - Rt / RSFa )2 - 1 ]0.5
1 - 0.528
= 1.123 [ ( 1 - 0.528 / 0.90 )2 - 1 ]0.5

= 0.619
CONTINUE WITH THE CALCULATION

Remaing Thickness Ratio R = 0.528


Allowable Remaining Strength Factor RSFa = 0,90
Factor Q =
0.619
Calculate Length for thickness averaging (L):

L=Q D x tmin

= 0.619 48 x 0.492

= 3.0 inches
CONTINUE WITH THE CALCULATION

Remaing Thickness Ratio R = 0.528


Allowable Remaining Strength Factor RSFa = 0,90
Factor Q = 0.619
Length for thickness averaging L = 3.0 inches

Longitudinal Critical Thickness Profile CTP


FCA

tmin = 0.492
L

s = flaw dimension
Flaw dimension s = 8.71 inches
L is considered for the 3 thinnest points (see later)
CONTINUE WITH THE CALCULATION

Remaing Thickness Ratio R = 0.528


Allowable Remaining Strength Factor RSFa = 0,90
Factor Q = 0.619
Length for thickness averaging L = 3.011 inches
Flaw dimension s = 8.71 inches

We need not consider the Longitudinal CTP because


tLmin < tmm - FCA
0.242 < 0.36 - 0.10 ( = 0.26)

We are now only concerned with the profile within the


flaw distance L taking the three thinnest adjacent points
CONTINUE WITH THE CALCULATION

Length for thickness averaging L = 3.0 inches


Divide into equal slices using the Grid Pitch
Dimension the L length and pitches

Longitudinal Critical Thickness Profile (CTP) within length L


0.48 0.49
0.55 tmm
0.47 0.36

1,5 1,5 1,5 1,5

L = 3.0
CONTINUE WITH THE CALCULATION
Longitudinal Critical Thickness Profile (CTP) within length L
0.48 0.49
0.55 tmm
0.47 0.36

1,5 1,5 1,5 1,5

L = 3.0
Calculate the Average Thickness (tam) over length L
This is done by taking the area and dividing by L:

tam = (0.55 + 0.36 + 0.36 + 0.48) x 1.5 = 0.438 inches


2 x L ( = 3.0)
CONTINUE WITH THE CALCULATION
Per paragraph 4.4.2.1.f.1:

tam - FCA = 0.438 - 0.10 = 0.338 inches


tCmin = 0.492
inches
tam - FCA > tCmin is FALSE

Per paragraph 4.4.2.1.f.2:

tmm - FCA = 0.36 - 0.10 = 0.26 inches


Max(-.5tmin, 0.10) = Max(0.246, 0.10) = 0.246 inches
tmm - FCA > Max(0.246, 0.10) is TRUE

BECAUSE ONE CONDITION IS FALSE, LEVEL 1


ASSESSMENT CRITERIA ARE NOT SATISFIED !
CONTINUE WITH THE CALCULATION
BECAUSE ONE CONDITION IS FALSE, LEVEL 1
ASSESSMENT CRITERIA ARE NOT SATISFIED !
We can derate the MAWP based on Level 1 assessment
Using the formula in ASME for pressure:

Set t = tam - FCA in the equation = 0.338 inches


SEt
MAWP =
Rc + 0.60.t
17500 x 0.85 x 0.338
=
24.10 + 0.60 x 0.338
= 207 psi

Therefore MAWP is derated from 300 psi down to 207 psi


CONTINUE WITH THE CALCULATION
Therefore MAWP is derated from 300 psi down to 207 psi

This is based upon the LEVEL 1 assessment !

WE CAN PERFORM A LEVEL 2 ASSESSMENT TO


PERFORM A MORE DETAILED ANALYSIS

Per paragraph 4.4.3.2.1.a.1:


tam - FCA = 0.438 - 0.10 = 0.338 inches
RSFa x tCmin = 0.90 x 0.492 = 0.443 inches
tam - FCA > RSFa x tCmin is FALSE
Per paragraph 4.4.3.2.1.b:
tamm - FCA = 0.36 - 0.10 = 0.260 inches
Max(0.5.tmin, 0,1) = Max(0.246, 0.1) = 0.246 inches
tamm - FCA > Max(0.5.tmin,0.1) is TRUE
CONTINUE WITH THE CALCULATION

Because LEVEL 2 assessment criteria are not met, we


must re-evaluate the MAWP according to LEVEL 2
requirements.
CONTINUE WITH THE CALCULATION
We can derate the MAWP based on Level 2 assessment
Using the formula in ASME for pressure:

Set tc = (tam - FCA) / RSFa in the equation


= (0.438 - 0.10) / 0.90 = 0.376 inches
SEtc
MAWP =
Rc + 0.60.tc
17500 x 0.85 x 0.376
=
24.10 + 0.60 x 0.376
= 230 psi

Therefore MAWP is derated from 300 psi down to 230 psi

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