1、 Fitness-For-Service Example Problem Manual API 579-2/ASME FFS-2 2009 AUGUST 11, 2009 SPECIAL NOTES This document addresses problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed. Nothing contained in this document is
2、 to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in this document be construed as insuring anyone against liability for infringement of letters pate
3、nt. Neither API nor ASME nor any employees, subcontractors, consultants, committees, or other assignees of API or ASME make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liabilit
4、y or responsibility for any use, or the results of such use, of any information or process disclosed in this document. Neither API nor ASME nor any employees, subcontractors, consultants, or other assignees of API or ASME represent that use of this document would not infringe upon privately owned ri
5、ghts. This document may be used by anyone desiring to do so. Every effort has been made to assure the accuracy and reliability of the data contained herein; however, API and ASME make no representation, warranty, or guarantee in connection with this document and hereby expressly disclaim any liabili
6、ty or responsibility for loss or damage resulting from its use or for the violation of any requirements of authorities having jurisdiction with which this document may conflict. This document is published to facilitate the broad availability of proven, sound engineering and operating practices. This
7、 document is not intended to obviate the need for applying sound engineering judgment regarding when and where this document should be utilized. The formulation and publication of this document is not intended in any way to inhibit anyone from using any other practices. Classified areas may vary dep
8、ending on the location, conditions, equipment, and substances involved in any given situation. Users of this Standard should consult with the appropriate authorities having jurisdiction. Work sites and equipment operations may differ. Users are solely responsible for assessing their specific equipme
9、nt and premises in determining the appropriateness of applying the Instructions. At all times users should employ sound business, scientific, engineering, and judgment safety when using this Standard. Users of this Standard should not rely exclusively on the information contained in this document. S
10、ound business, scientific, engineering, and safety judgment should be used in employing the information contained herein. API and ASME are not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning
11、 health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction. Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer
12、 or supplier of that material, or the material safety data sheet. The examples in this document are merely examples for illustration purposes only. They are not to be considered exclusive or exhaustive in nature. API makes no warranties, express or implied for reliance on or any omissions from the i
13、nformation contained in this document. All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, AP
14、I Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005. Copyright 2009 by the American Petroleum Institute and The American Society of Mechanical Engineers ii iii API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual FOREWORD The publication of the standard API 579-1/ASME
15、FFS-1 Fitness-For-Service, in July 2007 provides a compendium of consensus methods for reliable assessment of the structural integrity of industrial equipment containing identified flaws or damage. API 579-1/ASME FFS-1 was written to be used in conjunction with industrys existing codes for pressure
16、vessels, piping and aboveground storage tanks (e.g. API 510, API 570, API 653, and NB-23). The standardized Fitness-For-Service assessment procedures presented in API 579-1/ASME FFS-1 provide technically sound consensus approaches that ensure the safety of plant personnel and the public while aging
17、equipment continues to operate, and can be used to optimize maintenance and operation practices, maintain availability and enhance the long-term economic performance of plant equipment. This publication is provided to illustrate the calculations used in the assessment procedures in API 579-1/ASME FF
18、S-1 published in July, 2007. This publication is written as a standard. Its words shall and must indicate explicit requirements that are essential for an assessment procedure to be correct. The word should indicates recommendations that are good practice but not essential. The word may indicates rec
19、ommendations that are optional. The API/ASME Joint Fitness-For-Service Committee intends to continuously improve this publication as changes are made to API 579-1/ASME FFS-1. All users are encouraged to inform the committee if they discover areas in which these procedures should be corrected, revise
20、d or expanded. Suggestions should be submitted to the Secretary, API/ASME Fitness-For-Service Joint Committee, The American Society of Mechanical Engineers, Three Park Avenue, New York, NY 10016, or SecretaryFFSasme.org. Items approved as errata to this edition are published on the ASME Web site und
21、er Committee Pages at http:/cstools.asme.org. Under Committee Pages, expand Board on Pressure Technology Codes an intended precision is not implied. In general, the calculation precision should be equivalent to that obtained by computer implementation, rounding of calculations should only be done on
22、 the final results. 2.3 Tables and FiguresTable E2-1 - Part 3 Examples on Assessment for Brittle FractureExampleAssessmentLevelUnits Type of EquipmentGeometry Type or Description of Analysis 1 1 US Pressure Vessel- MAT calculation with PWHT 2 1 US Pressure Vessel- MAT calculation without PWHT3 1 US
23、Pressure Vessel- MAT calculation without PWHT4 1 US Pressure Vessel- MAT calculation with PWHT 5 2 US Pressure Vessel- MAT reduction vs P/Prating(Pressure Temperature Rating Basis)6 2 SI Pressure VesselCylinder MAT reduction vs S*E*/SE (Stress Basis) 7 1 and 2US Pressure VesselSphereMAT reduction vs
24、 S*E*/SE (Stress Basis) 8 2 US Pressure VesselSphereMAT reduction vs S*E*/SE (Stress Basis) 9 2 US Pressure VesselSphereMAT reduction vs operating pressure / hydrotest pressure103 US Demethanizer tower - Assessment based on fracture mechanics principlesof Part 9 Table E2-2 - Part 4 Examples on Asses
25、sment of General Metal LossExampleAssessmentLevelUnitsType of Equipment Geometry Location of Metal Loss Loading(s) Average Thickness based on1 1 and 2SI Heat exchanger Cylinder Away from msdInternal pressure Full vacuumPoint thickness reading2 1 and 2US Pressure VesselCylinder Away from msdInternal
26、pressureCritical thickness profiles 3 1 and 2SI Pressure VesselElliptical headAway from msdInternal pressureCritical thickness profiles 4 2 US Pressure VesselNozzleAt msd Internal pressureGiven in the dataAPI 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual 2-2 Table E2-3 - Part 5 Ex
27、amples on Assessment of Local Metal LossExampleAssessmentLevelUnitsType of Equipment Geometry Location of Metal Loss Loading(s) Type of Metal Loss 1 1 US Pressure VesselCylinder Away from msdInternal pressureLTA 2 1 and 2US Pressure VesselCylinder Away from msdInternal pressure2 Grooves3 2 US Pressu
28、re VesselCylinder Away from msdInternal pressure Supplementalloads LTA 4 2 US Pressure VesselCylinder Away from msdInternal pressureLTA 5 1 SI Pressure VesselCylinder Away from msdInternal pressureLTA 6 2 US Pressure VesselNozzleAt msd Internal pressureUniform LTA7 1 US Storage Tank Cylinder Away fr
29、om msdFill HeightLTA 8 1 US PipingElbow Away from msdInternal pressureUniform LTA9 2 US Pressure VesselCylinder Away from msdVacuumLTA Table E2-4 - Part 6 Examples on Assessment of Pitting Corrosion ExampleAssessmentLevelUnitsType of Equipment Geometry Loading(s) Type of PittingComment1 1 US Pressur
30、e VesselCylinder Internal pressureWidespreadpitting - 2 1 SI PipingCylinder Internal pressureWidespreadpitting - 3 2 US Horizontal Pressure Vessel Cylinder Internal pressure Supplementalloads Widely scattered pitting - 4 2 US Pressure VesselCylinder Internal pressureLocalized pittingLTA per Part 5 L
31、evel 15 2 US Pressure VesselCylinder Internal pressurePitting in LTA LTA per Part 5 Level 16 2 US Pressure VesselCylinder Internal pressureWidespread pitting Inside and outside- API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual 2-3 Table E2-5 - Part 7 Examples on Assessment of Bli
32、sters and HIC and SOHIC DamageHIC Damages ExampleHIC AreaLevelLocation in Thickness CommentService Condition 1 1 1 and 2Surface breakingLevel 2 per Part 5 Level 1Equipment will remain in hydrogen chargingservice2a1 Surface breakingCombined2bSub surface3 1 Surface breaking- 4 1 and 2Sub surfaceLevel
33、2 per Part 5 Level 13 1 1 Sub surface- Equipment will not remain inhydrogen charging service2 1 and 2Sub surfaceLevel 2 per Part 5 Level 1Blisters ExampleBlister LevelBulge DirectionCracking at PeripheryCrown Cracking or VentingComment2 A 1 and 2OutsideNoCrack Level 2 per Part 5 Level 1B 1 OutsideNo
34、Vent - C 1 InsideNoVent - D 1 and 2InsideNoCrack Level 2 per Part 5 Level 1E 1 InsideNoVent - F 1 InsideNoNo- G 1 and 2OutsideYes (Inward) Crack Level 2 per Part 5 Level 1H 1 and 2OutsideNoVent Level 2 per Part 5 Level 1Note: Common characteristics: - Type of Equipment: Pressure Vessel- Geometry: Cy
35、linder - Units: US - Loading: Internal pressure API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual 2-4 Table E2-6 - Part 8 Examples on Assessment ofWeld Misalignment and Shell DistortionsExampleAssessment LevelUnitsType of Equipment Geometry Loading(s) Type of DamageComment1 1 and
36、2US PipingCylinder Internal pressureWeld misalignmentPeaking2 2 US PipingCylinder Fluctuating internal pressureWeld misalignment PeakingFatigue assessment by: - elastic stress analysis andequivalent stress - elastic stress analysis and structural stress3 1and 2US Pressure VesselCylinder Internal pre
37、ssureOut-of-roundness Assessment based on Dmax-Dmin4 2 US Pressure VesselCylinder Internal pressureWeld misalignmentCenterline offset and peaking5 1 and 2US Pressure VesselCylinder Internal pressureOut-of-roundness Assessment based on radius expressedas a Fourier series 6 1 and 3US Pressure VesselSh
38、ell - Heads - Stiffening ringsInternal pressure VacuumconditionsGeneral shelldistortionLevel 3 based on Finite Element Analysis: - limit load analysis (elastic perfectly plastic material behavior) - check oflocal strain (elastic-plastic with strain hardening material behavior) - elastic buckling ana
39、lysis (check of stability of deformed shell) - check of fatigue requirements API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual 2-5 Table E2-7 - Part 9 Examples on Assessment of Crack-Like FlawsExampleAssessment LevelUnitsType of Equipment Geometry Loading(s) Type of Crack Comment1
40、 1 US Pressure VesselCylinder Internal pressure- Longitudinal- Semi-elliptical Shallow crack in parallel to weld seam2 1 SI Pressure VesselSphereInternal pressure- Circumferential - Semi-elliptical Deep crack perpendicular to weld seam3 1and 2US Pressure VesselCylinder Internal pressure- Semi-ellipt
41、ical - Oriented at 30 from principal directionFlaw length to be used in assessment4 1 and 2US Pressure VesselCylinder Internal pressure- Semi-elliptical - Oriented along bevel angleFlaw depth to be usedin assessment 5 1 and 2US Pressure VesselCylinder Internal pressure- Longitudinal- Semi-elliptical
42、 - Residual stressesdue to welding based on surface distribution- Uniform distribution alongthickness 6 1 and 2SI PipingCylinder Internal pressure Global bending moment- Circumferential - 360degree crack - Residual stressesdue to welding based on through-thickness distribution- Fourth order polynomi
43、al along thickness7 2 SI PipingCylinder Internal pressure Global bending moment- Circumferential - Semi-elliptical - Residual stressesidentical to those of example 9.6- Coefficients of polynomialcalculated byweight functionmethod8 3 US Pressure VesselCylinder Internal pressure- Longitudinal- Semi-el
44、liptical - Residual stressesidentical to those of example 9.5- Subcritical fatigue crack growth- Remaining life assessment 9 3 US - - - - Failure Assessment Diagram basedon actual material properties10 3 SI Pressure VesselNozzle Internal pressure Quarter-ellipticalAssessment based on elastic-plastic
45、 Finite Element Analysis API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual 2-6 Table E2-8 - Part 10 Examples on Assessment of ComponentsOperating in the Creep RangeExampleAssessmentLevelUnitsType of Equipment Geometry Loading(s) Comment1 1 US Pressure VesselCylinder Elliptical hea
46、dInternal pressure- Temperature excursion in the creep range- Check that damage is below the acceptable one2 1 US HeaterTubes Internal pressure- Heateroperating in the creep range- Excursion athigher temperature than designone- Calculation of overall damage in the complete expected life3 2 US Heater
47、Tubes Internal pressure- Same asexample 10.2 with the additionof - Calculation of remaining lifeusing Larson Miller parameters 4 3 US Pressure VesselCylinder Internal pressure- Vessel operating in the creep range- Longitudinalsemi-elliptical surface crack - Creep crack growth- Calculation of remaini
48、ng life using MPC Omega project dataTable E2-9 - Part 11 Examples on Assessment of Fire DamageExampleAssessmentLevelUnitsType of Equipment GeometryLoading(s) Comment1 1 US HEZ from observation after fire2 1 US Horizontal Pressure Vessel Cylinder Internal pressure SupplementalloadsHEZ from observation after fire2 Allowable stress from hardness results 3 1 US (+SI)Depropanizer tower - Internal pressure HEZ from observation after fire2 Allowable stre
