API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

PART 4
ASSESSMENT OF GENERAL METAL LOSS
EXAMPLE PROBLEMS
4.1
4.2
4.3
4.4

Example Problem 1 ......................................................................................................... 4-1

Example Problem 2 ......................................................................................................... 4-6
Example Problem 3 ....................................................................................................... 4-10
Example Problem 4 ....................................................................................................... 4-14

4.1 Example Problem 1

Internal corrosion on the cylindrical shell of a heat exchanger has been found during an inspection. Details
regarding the heat exchanger and inspection data are given below. The heat exchanger was constructed to
the ASME B&PV Code, Section VIII, Division 1, Edition 1989. Determine if the heat exchanger is suitable for
continued operation.
Vessel Data
Material

SA  516 Grade 60 Year 1989

Design Conditions

3.85 MPa @ 380q C and full vacuum @ 380q C

Inside Diameter

484 mm

Nominal Thickness

16 mm

Future Corrosion Allowance

2 mm

Weld Joint Efficiency

Tubesheet to tubesheet distance

1.0
1524 mm

--``,,`,,,,`,,,,`,,``,`````-`-`,,`,,`,`,,`---

4-1

API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

Inspection Data
Based on a visual inspection, the corrosion loss is characterized as general, and point thickness readings will
be used in the assessment (see paragraph 4.3.3.1 and 4.3.3.2). Point thickness readings were taken in
accordance with paragraph 4.3.3.2.
Table E4.1-1
Location

Thickness Reading

t , mm
13
12
11
13
10
12
11
12
13
13
11
12
12
13
13
--``,,`,,,,`,,,,`,,``,`````-`-`,,`,,`,`,,`---

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

4-2

API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

Perform a Level 1 assessment for internal pressure per paragraph - 4.4.2
a) STEP 1 Use the point thickness readings shown above; and determine the minimum measured
thickness, t mm , the average measured thickness, tam , and the Coefficient of Variation, COV. A template
for computing the COV is provided in Table 4.3 and is used in Table E4.1-2.
Table E4.1-2
Thickness Reading

--``,,`,,,,`,,,,`,,``,`````-`-`,,`,,`,`,,`---

Location

trd ,i , i 1 to N

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

13
12
11
13
10
12
11
12
13
13
11
12
12
13
13

tam

COV
b)

1 S
tam N  1

(trd ,i  tam ) 2

0.9333
-0.0667
-1.0667
0.9333
-2.0667
-0.0667
-1.0667
-0.0667
0.9333
0.9333
-1.0667
-0.0667
-0.0667
0.9333
0.9333

0.8711
0.0044
1.1378
0.8711
4.2711
0.0044
1.1378
0.0044
0.8711
0.8711
1.1378
0.0044
0.0044
0.8711
0.8711

trd ,i

12.0667

(t

rd ,i

 tam ) 2

12.9333

i 1

i 1

0.5

0.080

STEP 2 The COV equals 8.0%, which is less than 10%; therefore, the average thickness to be used in
the calculation is the average thickness of the thickness distribution, or

tam

12.0667 mm

LOSS
c)

1
N

trd , i  tam

tnom  tam

16  12.0667 3.9333 mm

STEP 3 Calculate the minimum required thickness (see Annex A).

c
tmin

PR
 SE  0.6 P 

L
tmin

PR
 2SE  0.4 P 

tmin

c
L

max tmin
, tmin

3.85(242  2  3.9333)
10.1670 mm
96.196(1.0)  0.6(3.85)
3.85(242  2  3.9333)
2(96.196)(1.0)  0.4(3.85)

4.9221 mm

max[10.1670, 4.9221] 10.1670 mm

d) STEP 4 Determine if the component is acceptable for continued operation.

Perform a Level 1 assessment using Table 4.4.

(tam  FCA 10.0667 mm) t (tmin

10.1670 mm) o False

Alternatively, the maximum allowable working pressure

MAWP based on the average thickness ( tam ) can be

compared to the design pressure with the design pressure as the criterion.
4-3

API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

tam  FCA 10.0667 mm

MAWP

SEt
R  FCA  LOSS  0.6t

 96.196 110.0667 
(242  2  3.9333)   0.6 10.0667 

3.813 MPa

3.813 MPa t 3.85 MPa o False

The Level 1 assessment criteria are not satisfied.
Perform a Level 2 assessment for internal pressure using Table 4.4.

(tam  FCA 10.0667 mm) t ( RSFa tmin

 0.9 10.1287 

9.1158 mm) o True

Alternatively, the maximum allowable working pressure ( MAWP ) based on the average thickness ( tam ) can
be compared to the design pressure with the design pressure as the criterion.

(tam  FCA)
RSFa

MAWP

10.0667
11.1852 mm
0.9

SEt
R  FCA  LOSS  0.6t

 96.196 111.1852 
(242  2  3.9333)   0.6 11.1852 

4.225 MPa t 3.85 MPa o True

Check the minimum measured thickness criterion.

(tmm  FCA 8 mm) t max[0.5tmin

tlim

max[0.2tnom

 0.2 16 

5.065, tlim ]

3.200, 2.500] 3.200 mm

8 mm t (max[5.065,3.200] 5.065 mm) o True

The minimum measured thickness criterion is satisfied.
The Level 2 assessment criteria for internal pressure are satisfied.

4-4

--``,,`,,,,`,,,,`,,``,`````-`-`,,`,,`,`,,`---

4.225 MPa