Perla - Ses - FFS V-102 (2016)

API-579 Level 3 Fitness for Service Assessment of
Degassing Vessel Subjected to Corrosion - V-102 –

Updated for October 2015 Inspection Data
Prepared for: Shell Global Solutions
Prepared by: Luiz C. Largura Jr, MSc

Date: 10 March 2016
Julian J. Bedoya, PE
SES Document No.: 1152570-PSP-PT-01 (Rev 2) / 1153331-PSP-RP-01 (Rev 0)

Table of Contents
• Executive Summary
• Summary
• Provided data: drawing, photographs and corrosion data
• API 579-1/ASME FFS-1 Methodology This document is an update of the previous project SES Doc No°
• Design Margin Factors 1152570-PSP-RP-01 (Rev 1) and 1152570-PSP-FIO-0001 Rev. 1.
based on the inspection results provided by SONOTEST (Oct 2015).
• Basic Model Details
• FEA Inputs As Such, this document is identified as;
• Geometry “1152570-PSP-RP-01 (Rev 2)” and
“115331-PSP-RP-01 (Rev 0)”
• Mesh
• Material Properties References:
SONOTES’s Inspection Services Report – Examinacion con
• Section Properties Ultrasonido Mecanizado Mapeo de Corrosion MPP Degassing
• Boundary Conditions Vessel V-102 - March 2015
SONOTES’s Inspection Services Report – Examinacion con
• Loads Ultrasonido Mecanizado Mapeo de Corrosion MPP Degassing
 Plastic Collapse Analysis Vessel V-102 - October 2015
 Buckling (external pressure) Collapse Analysis

• Results
• Conclusion
an employee-owned company
2
Executive Summary
• More recent V-102 inspection data (October 2015) was made
available to SES, and it was requested that the model be
updated to reflect this new inspection data.
• Additional assessments were performed to assess the fitness
for service of this vessel at its current state, as well as the
projected thickness expected for December, 2017 using the
client provided anticipated corrosion rate of 0.63 mm/year
(24.8 mils/year).
• The October, 2015 inspection reported a greater wall
thickness than reported in December,2013.
• Both the previous and anticipated (December, 2017) results
are documented in this report.
• A brittle fracture assessment was performed in accordance
with API 579-1/ASME FFS-1 Part 3, Level 2a
3
Executive Summary
• Internal Pressure Assessment for the Target Replacement Date of December
2017 (Level 3):
 The V-102 degasser has sufficient strength for operation at the internal design
pressure of 51 psi.
 The plastic collapse load is 255 psi, resulting in a load factor of 5.0, which exceeds
the required API 579-1/ASME FFS-1 load factor of 3.6.
 The load factor of 5.0 includes:
– Internal Pressure
– Hydrostatic Pressure (75% full of oil)
– Dead Weight
 Loss of containment due to accelerated corrosion (greater than the
anticipated rate) in the damaged region is still a concern
• External Pressure Assessment (Level 3)
 The V-102 degasser is not rated for a full vacuum load.
 Therefore, a partial vacuum of 7 psi is the highest acceptable external pressure
differential the degasser can experience.
 The buckling calculations considered:
– External Pressure
– Dead Weight (Vessel Full of Water)
4
Summary Conclusions
• Based on the internal pressure assessment:
 The V-102 degasser has sufficient strength for operation at the design internal
pressure of 51 psi, at an oil fill level of 75% (specific gravity of 0.7 was used)
 However, the V-102 degasser is not rated for the MAWP of 97 psi, at an 75% oil fill
level (specific gravity of 0.7).
 A MAWP of approximately 95 psi is the highest acceptable pressure using the
projected thickness expected by December 2017.
• Based on the external pressure buckling assessment:
 A partial vacuum of 7 psi is the highest acceptable external pressure differential the
degasser can experience.
• Based on the brittle fracture analysis:
 The vessel minimum allowable temperature (MAT) at maximum allowable working
pressure (MAWP) is -10°F.
 The V-102 operating conditions nor the lowest expected ambient temperature do not
present a potential brittle fracture risk to the vessel.
5
Recommendations
• To mitigate the potential for further wall loss; fully arrest the
corrosion under insulation (CUI) by appropriate surface
preparation and protective coating of the corroded areas.
• Follow-up inspections are recommended to validate the
anticipated 0.63 mm/year (24.8 mils/year) corrosion rate.
• If Petroregional wishes to mitigate the failure by external
pressure collapse scenario
 Two viable options for this can be evaluated:
– Addition of stiffener rings, to mitigate the vacuum condition
– Weld overlay deposition on the ID surface, to mitigate future corrosion – which will
also be beneficial for the restoration of the original MAWP of 97 psi, if desired.
6
Recommendations
• To mitigate the potential for full vacuum conditions:
 Ensure adequate vacuum vent capacity is provided on the vessel under all
operating and maintenance conditions (three examples are given below)
– Abnormal operation (loss of pressure control with continued liquid removal)
– Decontamination (steam-out with full condensing of the applied steam)
– Pressure (hydro) test liquid draining (provide high-point vent)
 Consider evaluating the vessel to include additional vacuum support rings to
meet the required full vacuum design condition.
7
Analysis Details
8
Summary
• PDVSA Petroreginal del Lago has observed corrosion on a Degasser V-102 (150-inch ID
and 0.630-inch nominal wall thickness) ASTM A 516 Grade 60. Preliminary wall
thickness measurements of the Vessel suggest that the lowest wall thickness is 0.236-
inch (6 mm).
• Stress Engineering Services, Inc. (Stress) was contracted to evaluate the mechanical
integrity of the pressure vessel V-102 and determine if the vessel has sufficient
remaining strength for continued operation according to the methodology below:
 API 579 Part 4 and 5, Level 3
 Perform an elastic-plastic analysis of the corroded pressure vessel with the
reported corrosion patches (API 579 Annex B.1.2.4)
 Perform a buckling analysis (vacuum) of the corroded pressure vessel with the
reported corrosion patches (API 579 Annex B.1.4)
 Perform a API 579 Part 3, Level 2a brittle fracture analysis to establish the
minimum allowable temperature (MAT)
9
Drawings and Design Data
Please note: the stiffening

rings were modeled as 152.4
mm tall (6.0”) and 20 mm 650°F
(0.787”) thick. This information
650°F
was provided by Shell in an e-
mail communication, as the 70°F (Ambient)
drawings were incorrect.
10
General View
11
API 579-1/ASME FFS-1
• The Elastic-Plastic method provided in API 579-1/ASME FFS-1, Part 4 and 5 was used for
evaluation of plastic collapse in pressurized components with metal loss.
 The plastic collapse load is the load at which structural instability occurs, and the
numerical analysis fails to converge.
 Evaluation of internal pressure (both, design pressure and MAWP), hydrostatic
pressure and dead weight.
 Evaluation of vacuum condition
• A design margin is determined using a safety margin of 3.6 as determined in API 579.
 4.0  Factored load cases in Table B1.4.
 0.9  Remaining strength factor (RSF) in Table 2.3. (Shell has indicated that they are
in agreement with the use of RSF for these results)
 Once the analysis converges at the factored loads, the acceptance criterion is met.
Stresses, strains and displacements are not necessarily accurate above this factored
load combination, and are for information only.
 The factored load combinations are relatively mesh insensitive, and represent plastic
collapse behavior. A mesh sensitivity study is not necessary in these analysis, as the
mesh is fine enough.
12
API 579-1/ASME FFS-1
• Brittle Fracture Analysis utilizes API 579-1/ASME FFS-1, Part 3

Level 2a
 Minimum Allowable Temperature (MAT) determined to be -10°F at MAWP.
13
Design Margin Factors – Both Load Cases
14
Basic Model Details
Model
 Software: Abaqus CAE 6.13
 Element type: 3D-Shell
 Element domain: Stress
 Element order: Linear System of Units
 Element nodes: 4 • Length: inch
 Integration points: 1 in plane, 5 through • Pressure: psi
the thickness • Deflection: inch
 Symbol: S4R • Stress: psi
Materials
• Shell, Heads, Stiffening Rings and saddles:
SA-516-60
15
FEA Inputs
• The material properties were modeled at a temperature of 650 ºF;
• Nozzles and their effects were excluded from the analysis;
• Shell, head and saddle materials are modeled as elastic-plastic with strain hardening (SA-516 Gr 60,
minimum properties per ASME Sec II – D);
• The vessel was modeled in the corroded condition based on the original design corrosion
allowance of 0.118 inch, except that the damaged regions were modeled using thicknesses from
the October, 2015 inspection report. A future corrosion allowance of 0.0537 inch (0.0248 inches
per year until December of 2017) was applied to the entire model;
• The analyses did not consider the pressure vessel to contain pits, cracks, or other flaws that could
contribute to a failure mode other than plastic collapse;
 Although pits were identified by Petroregional del Lago in December of 2013, they were not identified as
having a lower remaining wall thickness as the internal corrosion. Internal corrosion regions were modeled
as being 20-inches X 40-inches (508 mm X 1016 mm) using the minimum reported wall thickness for each
region.
• Loading from thermal events, piping, wind, seismic events, and fatigue have not been considered;
• Analysis was geometrically non-linear in all load steps;
16
Geometry
1% Ovality applied to
geometry (maximum Length = 552.76 inches
accepted ovality per ASME
criteria)
Nominal ID = 150 inches
Major axis
Minor axis
17
Mesh
Typical Element size = 2 inches

18
Material Properties
Elastic-plastic curve for SA-516 Grade 60 at 650 ⁰F
ASME Sec VIII - Div. 2 - Annex 3-D
100,000
90,000
80,000
True Stress (psi)
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
True Strain (in/in)
• Material properties at 650 ºF

 SA-516-60 (the entire geometry was modeled as elastic-plastic material)
– Modulus: 26,000 ksi @ 650°F
– Sy = 23.7 ksi @ 650°F
– Poisson’s Ratio: 0.3
– Density: 0.283 lbf / in3
19
Material Properties
Buckling Analysis
Elastic-plastic curve for SA-516 Grade 60 at 70⁰F
ASME Sec VIII - Div. 2 Annex 3-D
90,000
80,000
70,000
True Stress (psi)
60,000
50,000
40,000
30,000
20,000
10,000
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
True Strain (in/in)
• Material properties at 70 ºF
 SA-516-60 (the pressure vessel was modeled as elastic-plastic material)
– Modulus: 29,400 ksi @ 70°F
– Sy = 32 ksi @ 70°F
– Poisson Ratio: 0.3
– Density: 0.283 lbf / in3
20
Inspection Results
According to the inspection report (October 2015), the corroded area was divided into small areas that were
scanned. Those areas were named as showing on the left figure.
21
Section Properties
• Corroded areas in the FE model were idealized as a rectangular area with constant thickness (the minimum
thickness for each scan area). Scan areas 19, 20,21 and 22 did not have Oct. 2015 Data (2013 data was used).
Scan result Minimum thickness in each area (scan)
Thickness (inch)
Section Oct-15 Dec-17*
Scan20 0.47 0.41
Scan 22 Scan19 0.44 0.39
Scan 21
S5-01 0.51 0.45
S5-02 0.47 0.42
S5-03 0.42 0.37
S4-01 0.45 0.39
S4-02 0.42 0.36
S4-03 0.43 0.38
S3-01 0.46 0.41
S3-02 0.49 0.44
S3-03 0.52 0.47
S3-04 0.51 0.46
S3-05 0.48 0.42
S3-06 0.45 0.40
Scan 19
S2-01 0.42 0.37
Scan 20 S2-02 0.44 0.39
S2-03 0.51 0.45
S2-04 0.53 0.47
S2-05 0.52 0.46
S1-01 0.26 0.21
Scan22 0.50 0.44
Scan21 0.46 0.41
*Based on a corrosion rate of
0.63mm/year provided by Shell 22
Section Properties
The corrosion allowance of 0.118 inch was removed from the regions not reported in the inspection report.
Corroded regions were modeled as the October 2015 data less the projected corrosion until December 2017
using the provided corrosion rate.
Thickness (inch)
Section Oct-15 Dec-17*
Scan20 0.47 0.41
Scan19 0.44 0.39
S5-01 0.51 0.45
S5-02 0.47 0.42
S5-03 0.42 0.37
S4-01 0.45 0.39
S4-02 0.42 0.36
S4-03 0.43 0.38
S3-01 0.46 0.41
S3-02 0.49 0.44
S3-03 0.52 0.47
S3-04 0.51 0.46
S3-05 0.48 0.42
S3-06 0.45 0.40
S2-01 0.42 0.37
S2-02 0.44 0.39
S2-03 0.51 0.45
S2-04 0.53 0.47
S2-05 0.52 0.46
S1-01 0.26 0.21
Scan22 0.50 0.44
Scan21 0.46 0.41
*Based on a corrosion rate of
0.63mm/year provided by
Shell
23
Section Properties
24
Boundary Conditions
Gravity
Fixed Saddle Base Sliding Saddle Base
(Fixed all DOFs) (Fixed vertical DOF)
25
Loads – Plastic Collapse Analysis
Design Pressure
Internal-Pressure of IP = 51 psi
Hydrostatic Pressure considering 75% full of oil (SG = 0.7)
75% Fluid
Height
And Vessel Weight

26
Loads – Plastic Collapse Analysis
MAWP
Internal-Pressure of IP = 97 psi
Hydrostatic Pressure considering 75% full of oil (SG = 0.7)
75% Fluid
Height
And Vessel Weight

27
Loads – Buckling Collapse Analysis
External-Pressure of EP = 15 psi
Hydrostatic Pressure considering 100% full of water
And Vessel Weight

28
Results
Elastic Plastic Analysis
Internal Design Pressure (51 psi),
Hydrostatic Pressure and Vessel Weight
(Using 2013 Data, which is more
conservative than October 2015)
29
Required Load Factor of 3.6 (Requires Shell to Approve use of RSF)
von Mises Stress Hoop Stress Plastic Strain (PEEQ)
[psi] [psi] [inch/inch]
Deformation Scale Factor = 1.0

30
Internal Pressure vs. Total Equivalent Plastic Strain
(Internal and Hydrostatic Pressure, Content Weight and Vessel Weight)
Internal Pressure (or Load Factor) vs. Total Equivalent Plastic Strain
280 5.5
260
Load Factor (Dead Weight, Internal

Pressure and Hydrostatic Pressure)
5.0
Applied Internal Pressure (psi)
240
4.5
220
200 4.0
180 3.5
Unitless
160 Required 3.6 Safety
3.0
140 Margin (Requires Shell
120 approval of RSF) 2.5
100 2.0
80 1.5
60
1.0
40 51 psi Design Pressure and Nominal Loads (Dead
20 0.5
Weight, Internal Pressure and Hydrostatic Pressure)
0 0.0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Total Equivalent Plastic Strain (inch / inch)
31
Plastic Collapse Discussion
• Based on the API 579-1/ASME FFS-1 2007 Level 3 assessment:
 The V-102 degasser has sufficient strength for operation at the
internal design pressure of 51 psi.
 The plastic collapse load is 255 psi, resulting in a load factor of
5.0, which exceeds the required 4.0, or 3.6 with the Shell-
approved use of an RSF of 0.9.
 This load factor (design margin) of 5.0 considers:
– Dead Weight
32
Results
MAWP (97 psi), Hydrostatic Pressure and
Vessel Weight
(Using October 2015 Data)
33
Criterion for MAWP=97 psi not met (Load Factor = 3.53)

34
Criterion for MAWP not met (Load Factor = 3.53)

MAWP (or Load Factor) vs. Total Equivalent Plastic Strain
380 4.0
360

340
3.5
320
300
280 3.0
260 97 psi MAWP and Nominal Loads (Dead
240 Weight, Internal Pressure and Hydrostatic 2.5
Unitless
220 Pressure)
200 Required 3.6 Safety
2.0
180 Margin – Requires
160 Shell to approve
140 1.5
the use of a 0.9 RSF
120
100 1.0
80
60
40 0.5
20
0 0.0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Criterion for MAWP = 97 psi not met, therefore the MAWP was decreased to 95 psi
35
Results
New MAWP (95 psi), Hydrostatic Pressure
and Vessel Weight
36
New MAWP = 95 psi

37
New MAWP = 95 psi

MAWP (or Load Factor) vs. Total Equivalent Plastic Strain
380 4.0
360 MAWP = 95 psi

340
3.5
320
300
280 3.0
260 MAWP = 97 psi (not met)
240 2.5
Unitless
220
200 Required 3.6 Safety 97 psi MAWP and Nominal Loads (Dead 2.0
180 Margin – Requires Weight, Internal Pressure and Hydrostatic
160
140 Shell to approve Pressure) 1.5
120 the use of a 0.9 RSF
100 1.0
80
60
40 0.5
20
0 0.0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
38
Plastic Collapse Discussion
 The V-102 degasser is not rated for the MAWP of 97 psi.
 The plastic collapse load is 342 psi, resulting in a load factor of 3.53, which
does not met the required 3.6  3.53 x 97 = 342 psi
 However, the required load factor for a internal pressure considering the
remaining strength factor is 3.6.
 Therefore, a MAWP of 95 psi is the highest acceptable internal pressure the
degasser can experience, using the October, 2015 inspection data, and the
corrosion rate of 0.63 mm/year (24.8 mils per year)
 This load factor (design margin) of 3.6 considers:
– Dead Weight
39
Results
Buckling Collapse Analysis
External Pressure and Vessel Weight
40
Results for 15 psi External Pressure (Full Vacuum)
Load Factor 2.388 35.82 psi
Value required for full vacuum rating:
(4.0)x(RSF)x15psi = 54 psi
Criterion for full vacuum not met
[inch]
41
Deformation Scale Factor: 20.0
Results for 7 psi External Pressure (Partial Vacuum)
Load Factor 3.6  27 psi
Value required for full vacuum rating:
(4.0) x (RSF) x 7.7 psi = 27 psi
Partial Vacuum Criterion met for 7 psi
[inch]
42
Deformation Scale Factor: 10x
Buckling Discussion
 The buckling external pressure and dead weight combination is 2.388 x
15 psi (empty vessel weight, both loads concurrently applied)  35.82
psi
 However, the required load factor for a full vacuum rating considering
the remaining strength factor is 3.6.
 Therefore, a partial vacuum of 7 psi is the highest acceptable external
pressure differential the degasser can experience.
 The buckling calculations considered:
– External Pressure
– Dead Weight (Vessel 100% Full of Water)
43
Results
Brittle Fracture Analysis
44
Brittle Fracture Analysis
• Brittle Fracture Analysis utilizing API 579-1/ASME FFS-1, Part 3

Level 2a
 Minimum Allowable Temperature (MAT) determined to be -10°F
at MAWP.
• Vessel MAT compared to normal operating and minimum
expected ambient temperature exposure does not present a
brittle fracture potential.
45
Vessel Minimum Allowable Temperature (MAT)
46
Limitations of Analyses
• The analysis includes several limitations including:
 The material was modeled having the minimum yield strength and
tensile strength at 650⁰F with strain hardening (internal pressure
evaluations), and at ambient temperature conditions (buckling
evaluation), with strain hardening per ASME Sec II-D.
 The material is not embrittled (or of a low toughness).
 The vessel does not contain pits, cracks, or other flaws that could
contribute to a failure mode other than plastic collapse.
 Loading from snow, thermal events, piping, wind, seismic events, and
fatigue have not been considered.
47
Conclusions
• Based on the API 579-1/ASME FFS-1 2007 Level 3 Plastic Collapse (internal pressure)
assessment:
 The V-102 degasser has sufficient strength for operation at the design internal pressure of
51 psi, at a 75% liquid level (specific gravity of 0.7).
 The V-102 degasser is not rated for the MAWP of 97 psi, at an 75% oil level (specific gravity
of 0.7).
 A MAWP of 95 psi is the highest acceptable pressure.
 Loss of containment due to accelerated corrosion (greater than the anticipated rate) in the
damaged region is still a concern
• Based on the API 579-1/ASME FFS-1 2007 Level 3 Buckling Collapse (external pressure)
assessment:
 A partial vacuum of 7 psi is the highest acceptable external pressure differential the
degasser can experience.
• Brittle Fracture Analysis utilizing API 579-1/ASME FFS-1, Part 3 Level 2a
 Minimum Allowable Temperature (MAT) determined to be -10°F at MAWP.
 Vessel MAT compared to normal operating and minimum expected ambient temperature
exposure does not present a brittle fracture potential.
48
Thank You!
49
Limitations of This Report
This report is prepared for the sole benefit of the Client, and the scope is limited to matters
expressly covered within the text. In preparing this report, Stress Engineering Services, Inc. (SES)
has relied on information provided by the Client and, if requested by the Client, third parties.
SES may not have made an independent investigation as to the accuracy or completeness of
such information unless specifically requested by the Client or otherwise required. Any
inaccuracy, omission, or change in the information or circumstances on which this report is
based may affect the recommendations, findings, and conclusions expressed in this report. SES
has prepared this report in accordance with the standard of care appropriate for competent
professionals in the relevant discipline and the generally applicable industry standards.
However, SES is not able to direct or control operation or maintenance of the Client’s
equipment or processes.
Rev Date Description Originator Checker Reviewer

Luiz C. Largura
Report issued for PN: 1152570 – “1152570-PSP-PT-
1 16-Mar-2014 Ralph King RC Biel
0001 (Rev 1)”
Julian Bedoya
B 26-Feb-2016 Issued for internal review Luiz C. Largura Julian Bedoya
LC Largura
0 10-Mar-2016 Issued for client use (PN: 1153331-PSP-RP-01) J Norris
J Bedoya
SES Document No.: 1152570-PSP-PT-01 (Rev 2) / 1153331-PSP-RP-01 (Rev 0)

50
Luiz Carlos Largura Jr. Julian J. Bedoya, P.E.
Luiz.Largura@stress.com Julian.Bedoya@stress.com
13610 Westland East Blvd 13800 Westfair East Drive
Houston, TX 77041-1101 Houston, TX 77041-1101
Office: 281.955.2900 Office: 281.955.2900
Houston Calgary Cincinnati New Orleans Baton Rouge Singapore
51

Perla - Ses - FFS V-102 (2016)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Perla - Ses - FFS V-102 (2016)

Uploaded by

Copyright:

Available Formats

API-579 Level 3 Fitness for Service Assessment of

Degassing Vessel Subjected to Corrosion - V-102 –

Prepared for: Shell Global Solutions

Prepared by: Luiz C. Largura Jr, MSc

SES Document No.: 1152570-PSP-PT-01 (Rev 2) / 1153331-PSP-RP-01 (Rev 0)

 Buckling (external pressure) Collapse Analysis

Please note: the stiffening

• Brittle Fracture Analysis utilizes API 579-1/ASME FFS-1, Part 3

• Nozzles and their effects were excluded from the analysis;

• Analysis was geometrically non-linear in all load steps;

Nominal ID = 150 inches

Typical Element size = 2 inches

• Material properties at 650 ºF

Hydrostatic Pressure considering 75% full of oil (SG = 0.7)

And Vessel Weight

Hydrostatic Pressure considering 75% full of oil (SG = 0.7)

And Vessel Weight

Hydrostatic Pressure considering 100% full of water

And Vessel Weight

von Mises Stress Hoop Stress Plastic Strain (PEEQ)

[psi] [psi] [inch/inch]

Deformation Scale Factor = 1.0

Load Factor (Dead Weight, Internal

[psi] [psi] [inch/inch]

Deformation Scale Factor = 1.0

Criterion for MAWP not met (Load Factor = 3.53)

Load Factor (Dead Weight, Internal

[psi] [psi] [inch/inch]

Deformation Scale Factor = 1.0

New MAWP = 95 psi

Load Factor (Dead Weight, Internal

• Brittle Fracture Analysis utilizing API 579-1/ASME FFS-1, Part 3

 The material is not embrittled (or of a low toughness).

Rev Date Description Originator Checker Reviewer

SES Document No.: 1152570-PSP-PT-01 (Rev 2) / 1153331-PSP-RP-01 (Rev 0)

Houston Calgary Cincinnati New Orleans Baton Rouge Singapore

You might also like