2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

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SKG 15 Materials, Corrosion & Inspection Engineering

Fitness-for-Service L1
Part 2: Basic thinning assessments shell & head

Outline
1. Objective
2. Basic formulas & nomenclatures as per ASME Section VIII
3. Exercises based on API 510
4. Assessment based on API 579
1. To practice performing simple thinning assessments on basic pressure vessel
components i.e. shell & head:
Uniform corrosion on shell
Localized corrosion on shell
Corrosion on heads
Scattered pits

Objective
Outline
1. Objective
2. Basic formulas & nomenclatures as per ASME Section VIII
3. Exercises based on API 510
4. Assessment based on API 579
Cylindrical shell
Spherical shell
Ellipsoidal head
Spherical head
D = head inside diameter
E = welding efficiency
L = spherical head internal radius
P = internal pressure
R = shell internal radius
S = allowable stress
t = thickness

Basic formulas & nomenclatures as per ASME Section VIII
Outline
1. Objective
2. Basic formulas & nomenclatures as per ASME Section VIII
3. Exercises based on API 510
4. Assessment based on API 579
Lets try some problems to assess the following;
Uniform corrosion on shell
Localized corrosion on shell
Corrosion on heads
Scattered pits
Assessment of inspection findings as per API 510
Given the following table from API 510
Remaining
Life
Internal
inspection
interval
Remaining
Life
External
inspection
interval
>20 years 10 years >10 years 5 years
4 20 years life 4 10 years life
2 4 years 2 years 2 4 years 2 years
0 2 years Full life 0 2 years Full life
Uniform corrosion on shell as per API 510
In April 2002, thickness was 10mm
In April 2005, thickness reduced to 9.7mm
The minimum required thickness for vessel is 8.2mm
Determine the following;
1. Remaining corrosion allowance
2. Corrosion rate
3. Remaining life (from April 2005)
4. Internal inspection interval & next inspection date
5. External inspection interval & next inspection date

Uniform corrosion on shell as per API 510
RULES: Least thickness is averaged over a longitudinal length of;
Smaller of vessel diameter or 20, for diameter up to 60
Smaller of vessel diameter or 40, for diameter above 60
Localized corrosion on shell as per API 510
Given the following;
Vessel diameter is 96 (2.44m)
Required thickness is 7.0mm
Distance s is 36
Distance c is 30
Localized corrosion on shell as per API 510
Data from April 2002
Point
Thickness
(mm)
Point
Thickness
(mm)
1 9.8 a 9.8
2 9.6 b 9.6
3 9 c 9
4 8.7 d 8.7
5 9 e 9
6 9.1 f 9.1
7 9.3 g 9.2
Data from April 2005
Point
Thickness
(mm)
Point
Thickness
(mm)
1 9.1 a 8.9
2 9 b 8.7
3 8.6 c 8.5
4 8.4 d 8.4
5 8.8 e 8.5
6 8.9 f 8.6
7 9 g 8.9
Determine the following;
1. Remaining corrosion allowance
2. Corrosion rate
3. Remaining life (from April 2005)
4. Internal inspection interval & next inspection date
5. External inspection interval & next inspection date
1
2
3
4
5
6
7
a b c d e f g
s
c
80%
10%
10%
A
B
Localized corrosion on head as per API 510
Remember the following rules;
If corrosion happens at knuckle area (Area A), use appropriate head formula
If corrosion happens at central area (Area B), use spherical head formula AND radius R
shall be equal to K
1
D, where D is the shell diameter and K
1
is from table 5-1 of API 510
D/2h
(h = depth of head)
K
1
3.0 1.36
2.4 1.08
2.0 0.90
1.6 0.73
1.2 0.57
Problem : After 5 years in operation corrosion was found on Area A with a minimum
thickness of 0.5
Determine the following:
1. Corrosion rate
2. Corrosion allowance
3. Remaining life
4. Internal inspection interval
5. External inspection interval
80%
10% 10%
A
B
Localized corrosion on head as per API 510
Given the following basic data;
Head type : 2-1 elliptical head
P = 200 psi
E = 1.0
S = 20,000 psi
D = 80
Original thickness = 0.66
Problem : After 5 years in operation corrosion was found on Area B with a minimum
thickness of 0.46
Determine the following:
1. Corrosion rate
2. Corrosion allowance
3. Remaining life
4. Internal inspection interval
5. External inspection interval
80%
10% 10%
A
B
Localized corrosion on head as per API 510
Given the following basic data;
Head type : 2-1 elliptical head
P = 200 psi
E = 1.0
S = 20,000 psi
D = 80
Original thickness = 0.66
Scattered pits..the rule
The remaining thickness shall not be less than the required thickness of the shell
Scattered pits on shell as per API 510
Given the following;
P = 200 psi
E = 1.0
S = 20,000 psi
D = 96
Original thickness = 0.6
Problem : What is the maximum pit depth allowed?
Outline
1. Objective
2. Basic formulas & nomenclatures as per ASME Section VIII
3. Exercises based on API 510
4. Assessment based on API 579
Lets try something harder..using API 579
Given the following;
P = 300 psi
D = 100
S = 18,000 psi
E = 1.0
Original thickness = 1.25

Minimum required thickness;
" 842 . 0
) 300 6 . 0 ( ) 1 18000 (
50 300
6 . 0

P SE
PR
t
Assessment of inspection findings as per API 579
c
s
c
s
Inspection established the following;
Localized internal thinning area with a
longitudinal length (s) 4 & circumferential
length (c) 3.7
Lowest reading within area = 0.5
Corrosion rate = 0.025 per year
Assessment of inspection findings as per API 579
Question : Can the vessel be safely operated if the
next scheduled inspection is in 5 years time?
Step 1 Find out required radius - R
c
FCA = Future corrosion allowance
= Corrosion rate x time until next shutdown
= 0.025 inch/year x 5 years
= 0.125 inch

R
c
= R + FCA
= (100 x ) + 0.125 inch
= 50.125 inches
Assessment of inspection findings as per API 579
Step 2 Find out minimum required thickness to withstand load in circumferential
direction
" 844 . 0
) 300 6 . 0 ( ) 1 18000 (
125 . 50 300
6 . 0
min

P SE
PR
t
c
c
Assessment of inspection findings as per API 579
Step 3 Find out minimum required thickness to withstand load in longitudinal
direction
" 416 . 0
) 300 4 . 0 ( ) 1 18000 (
125 . 50 300
4 . 0
min

P SE
PR
t
c
L
Assessment of inspection findings as per API 579
Step 4 Find out t
min
" 844 . 0 and of larger
min min min

c L
t t t
Assessment of inspection findings as per API 579
Step 5 Determine the parameter R
t
t
mm
= the minimum thickness measured at the thinned area
= 0.5 inch
443 . 0
844 . 0
125 . 0 5 . 0
min

t
FCA t
R
mm
t
Assessment of inspection findings as per API 579
Step 6 Determine the parameter

s = defect longitudinal length
= 4 inch
559 . 0
844 . 0 100
4 285 . 1 285 . 1
min

Dt
s

Assessment of inspection findings as per API 579

Step 7 Refer to figure 5.6 to determine longitudinal acceptance

From this curve, the minimum
value of R
t
required is about 0.38,
which is smaller than the calculated
value of 0.443

PASS
Assessment of inspection findings as per API 579
Step 8 Determine c/D

c = defect circumferential length
= 3.7 inch
037 . 0
100
7 . 3

D
c
Assessment of inspection findings as per API 579
Step 9 Refer to figure 5.7 to determine circumferential acceptance

From this curve, the minimum
value of R
t
required is about
0.2, which is smaller than the
calculated value of 0.443

PASS
Assessment of inspection findings as per API 579
Conclusion..
c
s
The vessel can be safely operated until the next
scheduled inspection in 5 years time
Assessment of inspection findings as per API 579
Lessons learned..
c
s
This is merely a Level 1 Fitness For Service Assessment
the simplest of all assessments by API 579
Level 2 & Level 3 assessments can get more
complicated
Assessment of inspection findings as per API 579
End of presentation
Thank you