API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

ABC-1234
Vessel

Opolo
Equipment:
Date:

Separator
29th August 2014

Introduction

The following Level 1 and Level 2, Fitness-For-Service assessments were carried out on Grid Refe
01, in accordance with API 579-1, Part 4, for Type 'A' pressurized components subject to general
resulting from internal corrosion, using the methods outlined in API 579-2, 4.2. The assessement
are based on a thickness averaging approach. As per API 579-2, 4.2, the longitudinal weld seam
area of assessed corrosion is not considered to be a major structural discontinuity, though the we
efficiency of 0.85 has been taken into account.
Summary

The Level 1 assessment criteria are not satisfied due to the average measured thickness in the lo
The Level 2 assessment criteria are not satisfied.
Nomenclature
CTP
D
FCA
L
LOSS
Q

Critical Thickness Profile.

inside diameter of the shell corrected for LOSS and FCA as applicable.
Future Corrosion Allowance (see API 579-1, Annex A, paragraph A.2.7).
length for thickness averaging along the shell.
amount of uniform metal loss away from the local metal loss location at the time of the as
actor used to determine the length for thickness averaging based on an allowable Remain
(see API 579-1, Part 2) and the remaining thickness ratio, Rt (see API 579-1, Table 4.5).

Rt
RSFa

remaining thickness ratio.

allowable remaining strength factor (see API 579-1, Part 2).

tcam

average measured wall thickness of the component based on the circumferential CTP dete
of the inspection.

tsam

average measured wall thickness of the component based on the longitudinal CTP determ
the inspection.
corroded wall thickness.
limiting thickness.
minimum required wall thickness of the component (see API 579-1, Annex A, paragraph A.

tc
tlim
tmin
tCmin

minimum required thickness of a conical or cylindrical shell based on the stresses in the ci
hoop direction (see API 579-1, Annex A, paragraph A.2).

tLmin

minimum required thickness of a conical or cylindrical shell based on the stresses in the lo
(see API 579-1, Annex A, paragraph A.2).
minimum measured thickness determined at the time of the inspection.
nominal or furnished thickness of the component adjusted for mill undertollerance as appl
uniform thickness away from the local metal loss location established by thickness measu
of the assessment.

tmm
tnom
trd

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

Opolo
Equipment:
Date:

ABC-1234
Vessel

Separator
29th August 2014
Note
s

Vessel Data
Material
Maximum Allowable Stress (S)
Design Conditions (P)
Inside Diameter (ID)
Inside Diameter (D)
Inside Radius (IR)
Inside Radius (R)
Nominal Thickness (tnom)
Corrosion Allowance (FCA)
Weld Joint Efficiency (E)

SA-516, Grade 70, year 1999

20000
psi
300
psig @ 350 F
48.000
in
48.200
in
24.000
in
24.100
in
0.750
in
0.100
in
0.85

including FCA
excluding FCA
including FCA
excluding FCA

Inspection Data

The grid used for the inspection and the thickness readings are shown below. The grid spacing se
Equipment Inspector in the circumferential and longitudinal directions is 1.5 inches based on the
Figure 1
Inspection Grid

C
1

C
2

C
3

C
4

C
5

C
6

C
7

Grid Refer
CML-01

C
8

M1
M2
M3
Vessel Shell

M4
M5

Weld
Seam

M6
M7

Table 1 - Inspection Data (in)

Longitudinal
Inspection
Planes
M1
M2
M3
M4
M5
M6
M7
Longitudinal
CTP

Circrcumferential Inspection Planes

C1
0.75
0.75
0.75
0.75
0.75
0.75
0.75

C2
0.75
0.48
0.57
0.61
0.62
0.57
0.75

C3
0.75
0.52
0.59
0.47
0.59
0.59
0.75

C4
0.75
0.57
0.55
0.58
0.58
0.61
0.75

C5
0.75
0.56
0.59
0.36
0.57
0.57
0.75

C6
0.75
0.58
0.60
0.58
0.48
0.56
0.75

C7
0.75
0.60
0.66
0.64
0.62
0.49
0.75

C8
0.75
0.75
0.75
0.75
0.75
0.75
0.75

0.75

0.48

0.47

0.55

0.36

0.48

0.49

0.75

Circumferential
CTP
0.75
0.48
0.55
0.36
0.48
0.49
0.75

Longitudinal
0.75
CTP
Grid
Spacing
0

0.48

0.47

0.55

0.36

0.48

0.49

0.75

1.5

4.5

7.5

10.5

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

Opolo
Equipment:
Date:

ABC-1234
Vessel

Separator
29th August 2014

Perform a Level 1 assessment for internal pressure as per API 579-1, paragraph 4.4.2
(a) STEP 1 - Calculate the minimum required thickness.

C
tmin

PR

(SE 0.6P)

0.430 in

L
tmin

PR

(SE 0.4P)

0.212 in

C
L
tmin max[tmin
, tmin
]

API 579 referenc

0.430 in

(b) STEP 2 - Thickness profiles are provided, the data for thickness readings is in Table 1, above.
0.360 in

tmm

(c) STEP 3 - Determine wall thickness to be used in the assessment.

tc trd FCA

0.650 in

(d) STEP 4 - Compute the remaining thickness ratio, Rt

Rt

tmm FCA

(tc )

0.400 in

(e) STEP 5 - Compute the length for thickness averaging from API 579-1, Table 4.5,
with Rt =
0.400 in
RSFa =
0.9
Table 2.3
The equation for Q is:
2

1
R
t
Q 1.123
1
(1 Rt / RSFa )

Q=

0.4581

0.5

for Rt < RSFa

Q=

50

for Rt RSFa

for Rt < RSFa

Q=

50

for Rt RSFa

Is Rt < RSFa YES

Q=

Is Rt RSFa NO

0.4581

Table 4.5

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

Opolo
Equipment:
Date:

ABC-1234
Vessel

with LOSS =

Separator
29th August 2014

0.000 in

D ID 2(LOSS FCA)

48.200 in
2.564 in

L Q Dtc

(f) STEP 6 - Establish the Critical Thickness Profiles (CTP's) from the thickness profile data. Deter
measured thickness tsam based on the longitudinal CTP and the average measured thickness
circumferential CTP.
Longitudinal CTP
Figure 2: Longitudinal Critical Thickness Profile (in)

0.75

tleft
0.55
0.48

0.47

tright
t1

tmm

t2

0.48

0.49

0.36

L = 2.564 in

Grid spacing =
tmm =
tleft =
tright =
L=

1.5 in
0.360 in
0.550 in
0.480 in
2.564 in

(L / 2)

(grid spacing)

t1 tmm (tleft tmm)

t1 =

0.522 in

t2 =

0.463 in

(L / 2)

(grid spacing)

t2 tmm (tright tmm)

0.75

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

Opolo
Equipment:
Date:

ABC-1234
Vessel

Separator
29th August 2014

The area method is used to determine the average thickness.

(t1 tmm)
(L / 2)
2

(tmm t2 )
(L / 2)
2

A1

A2

A1 =

0.566 in2

A2 =

0.527 in2

A1 + A2 =

1.093 in2

s
tam

(A1 A2 )
L
0.426 in

s
tam

Circumferential CTP
Figure 3: Circumferential Critical Thickness Profile (in)

0.75

tleft
0.55
t3

0.48

tmm
0.36

L = 2.564
in

Grid spacing =
tmm =
tleft =
tright =
L=

1.5 in
0.360 in
0.550 in
0.480 in
2.564 in

tright
t4

0.48

0.49

0.75

(L / 2)

(grid spacing)

(L / 2)

(grid spacing)

t3 tmm (tleft tmm)

t4 tmm (tright tmm)

t3 =

0.522 in

t4=

0.463 in

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

Opolo
Equipment:
Date:

ABC-1234
Vessel

Separator
29th August 2014

The area method is used to determine the average thickness.

(t3 tmm)
(L / 2)
2

A3

(tmm t4 )
(L / 2)
2

A4

A3 =

0.566 in2

A4 =

0.527 in2

A3 + A4 =

1.093 in2

c
tam

(A3 A4 )
L

c
tam

0.426 in

(g) STEP 7 - Determine the acceptability for continued operation using Level 1 criteria in API 579
The average measured thickness acceptance is used in this example.
s
tam
FCA

0.326 in

c
tmin

0.430 in

s
c
tam
FCA tmin

NO

c
tam
FCA

0.326 in

L
tmin

0.212 in

c
L
tam
FCA tmin

from STEP 1

from STEP 1

YES

The Level 1 assessment criteria are not satisfied due to the average measured thickn

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

Opolo
Equipment:
Date:

ABC-1234
Vessel

Separator
29th August 2014

Check the minimum thickness criteria in API 579-1, Table 4.4

tlim max[0.2tnom, 0.10 inches]

tlim

0.150 in

tmm FCA

0.260 in

max[0.5tmin , tlim ]=

0.215 in

tmm FCA max[0.5tmin , tlim ]

YES

The minimum thickness criteria are satisfied

Level 1 Assessment Summary

The Level 1 criteria are not satisfied, perform a Level 2 Assessment using API 579-1, Table 4.4

Level 2 Assessment
s
(tam
FCA)

0.326 in

RSFa tmin

0.387 in

s
(tam
FCA) (RSFa tmin )

NO

The Level 2 criteria are not satisfied

Page 1
Opolo

ervice assessments were carried out on Grid Reference: CMLpe 'A' pressurized components subject to general metal loss
hods outlined in API 579-2, 4.2. The assessement procedures
As per API 579-2, 4.2, the longitudinal weld seam within the
be a major structural discontinuity, though the weld joint

d due to the average measured thickness in the longitudinal CTP

the local metal loss location at the time of the assessment.

hickness averaging based on an allowable Remaining Strength Factor
g thickness ratio, Rt (see API 579-1, Table 4.5).

component based on the circumferential CTP determined at the time

component based on the longitudinal CTP determined at the time of

component (see API 579-1, Annex A, paragraph A.2).

or cylindrical shell based on the stresses in the circumferential or
or cylindrical shell based on the stresses in the longitudinal direction

mponent adjusted for mill undertollerance as applicable.

etal loss location established by thickness measurements at the time

Page 2
Opolo

including FCA
excluding FCA
including FCA
excluding FCA

ess readings are shown below. The grid spacing set by the Fixed
longitudinal directions is 1.5 inches based on the corrosion profile.
Grid Reference
CML-01

Grid
Spacing
0
1.5
3
4.5
6
7.5
9

Page 3
Opolo

API 579 reference

e data for thickness readings is in Table 1, above.

Page 4
Opolo

files (CTP's) from the thickness profile data. Determine the average
nal CTP and the average measured thickness tcam based on the

Page 5
Opolo

Page 6
Opolo

ntinued operation using Level 1 criteria in API 579-1, Table 4.4.

atisfied due to the average measured thickness in the longitudinal CTP

Page 7
Opolo

Level 2 Assessment using API 579-1, Table 4.4