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By
Mohammad M. Megahed
Mohammad S. Attia
Faculty of Engineering – Cairo University – Egypt
Stress Analysis
Finite Element Analysis
Metallurgy
Materials Engineering
Non-Destructive Examinations (NDE)
Corrosion Science and Engineering
Fracture Mechanics
Advantages of FFS Assessment
remaining strength 15
0m
m
nn
e c ti on
mm
factor for pipes with
o
3 45
gi dC
Ri
increasing levels of
future corrosion W1 2220N
1st Yield and Limit Pressures for corroded pipes with
FCA = 0.4, 1, 1.6 mm compared to as –new pipe
240
Future
FCA=0.4mm
Limit
Effective Stress [MPa]
200 Uncorroded
Corrosion
Pressure RSF
Py=13.5 MPa
160
Allowance
(MPa)
120
FCA (mm)
80
0 37 100%
PL=37 MPa
PL=18 MPa
40
0.4 18 49%
1.0 15 41 %
0
0 5 10 15 20 25 30 35 40
1.6 12 32%
Internal Pressure [MPa]
240
Effective Stress [MPa]
200
160
FCA=0.4mm
120 FCA=1mm
FCA=1.6mm
80
40
0
0 2 4 6 8 10 12 14 16 18 20
Future
Limit
Corrosion
Pressure RSF
Allowance
(MPa)
FCA (mm)
0 37 100%
(b)
0.4 18 49%
1.0 15 41 %
1.6 12 32%
FFS Parts Addressing Corrosion Assessment
0.8
Toughness Ratio Kr
Unacceptable Region
Cut-off for steels
0.6 with yield plateau
0
0 0.5 1 1.5 2 2.5
P
Load Ratio L P ref
ys
r
17
Matching between Degradation
Mechanisms and FFS Parts
Case-1
Fitness-For Service
Assessment of Two
Regeneration Columns
Suffering from Wall
Cracking
Introduction
A gas plant implements a sweetening process, in which
CO2 and small amounts of H2S are stripped-off the
produced gas through two Lean Benfield System Trains
# A, B. The process is conducted inside a vertical tower;
known as a “Regeneration Column”. Geometry of the
column: height = 28 m above the skirt, Di = 3 m, wall
thickness =16 mm
The lower 18.6 m is fabricated from carbon steel (ASTM-
A516- Grade 70) with yield strength around 400 MPa,
while the upper 10 m is fabricated from stainless steel
316.
A passivation technique of the inner wall was adopted
through circulating a Vanadium Pent-Oxide (V2O5)
through the lower section the regenerator column;
supposed to be effective for a normal duration of 5
years
Construction of the Regeneration Column
Design Conditions and Loads
Design Conditions
Design Pressure Pd = 4.1 barg,
Operating pressure Po = 1.6 barg,
Po reduced to = 0.4 barg.
Design temp. Td = 140 oC ,
Operating temp. To = 115 oC.
Column weight +Contents = 1350 kN
Maximum eccentricity of weight = 100 mm
Maximum wind speed = 31 m/sec
Estimation of Stresses in the wall due to Operating Loads:
Hoop stress due to 0.4 barg = +4 MPa
Axial stress due to 0.4 barg = +2 MPa
Axial stress due to column weight = -9 MPa
Stress due to weight eccentricity = + 1.2 MPa
Highest hoop stress due to P = 4 MPa = 1% of Sy
Highest compressive stress due to all loads = -8 MPa = 2 %
of Sy
Problem History and Inspection Data
History
Year 1999: commissioning of the two columns: A, B
Year 2002: Uniform pitting observed at C.S./S.S. interface of
deepest pit =1.5 mm. Pits attributed to galvanic corrosion.
Year 2004: Leaks observed at small pinholes at weld locations in
the CS section, e.g. at shell girth welds, and piping connections.
Years 2004-2006: Increasing number of leaks + observed corrosion
in the vessel wall under the insulation
Damage was observed only in column A but not in column B
Most Important Inspection Results (April 2006)
Vessel Body: Branched long through-thickness crack at the girth
weld of Strakes 4 and 5.
Down-Comer: Non-penetrating internal circumferential cracks at the
welds connecting the down- comer piping to the vessel wall with
max. length of 220 mm.
N5 and N6 Nozzles: Non-penetrating internal circumferential cracks
at the HAZ of the welds connecting nozzles to vessel wall, lengths up
to 150-230 mm
Girth Weld Crack Defects
Through-Thickness
Branched crack ~80
mm long at shell
girth weld joining
strakes 4 and 5.
Examples of Flaws at Nozzle N5
0.5 1
Acceptable
0
0 0.5 1 1.5 2 2.5
P
Load Ratio LPr ref
ys
30
Variation of Stress Intensity Factor with Crack Depth
for Down-Comer Cracks
600
Through-thickness crack
Stress Intensity Factor (KI )
500 2c
a
400 t
[MPa m ]
300
200
Material Fracture Toughness
KIC=131.8 MPa m
100
0 a=0.8t
0 2 4 6 8 10 12 14 16
Crack Depth (a) [mm]
31
FFS of the Branched Through-Thickness Girth
Weld
0.8
Toughness Ratio Kr
0.6
0.4
0.2
0
0 0.5 1 1.5 2 2.5
P
Load Ratio LPr ref
ys
Reboiler Vapour Return Nozzle N5 – Circumferential Crack
X58 with L= 150 mm is the most Serious
X58 =150 mm
X43 =120 mm
FFS of Crack N58 with L =150 mm in Nozzle N5 for
increasing Values of Crack Depth
3
Case # a [mm] K iR MPa m K iR / K mat
1 8 96.6 0.733
2.5 2 11.2 114.8 0.871
Toughness Ratio Kr
0.5 1
Acceptable
0
0 0.5 1 1.5 2 2.5
P
Load Ratio L P ref
ys
r
Conclusions Recommendations
Stresses due to Operating loads were found to be very
small. Residual stresses are present at the welds due
to absence of PWHT. Presence of residual stresses and
the lack of effectiveness of the passivation technique
are the main causes of observed cracking located
primarily at or near the welds in the CS section of the
tower(s).
Corroded
Region
UT Grid size:
10 mm in axial direction
46 mm in circumferential
direction
tminc = 3.76 mm
tminL = 2.64 mm
values of FCA
Also note the
global
instability for
the case of (b)
FCA = 1.6 mm
©
Limit Pressures for the Corroded Pipe for Various
FCA values: (a) 0.4 mm, (b) 1 mm, (c) 1.6 mm
Variation of Effective Strain with Pressure for Corroded Pipes
for Various FCA values: (a) 0.4 mm, (b) 1 mm, (c) 1.6 mm
Level-3 Assessment of Global and Local Instability
Decision
Pressure FCA Global Instability Local Instability
Level adopted for
Instability Check (mm)
1.5xRSFa x (P+W) 1.7xRSFa x (P+W)
Pass
= 1350 psi
225 psi