1、Fitness-For-ServiceExample ProblemManualAPI 579-2/ASME FFS-2 2009AUGUST 11, 2009Fitness-For-Service Example Problem Manual API 579-2/ASME FFS-2 2009 AUGUST 11, 2009 ii SPECIAL NOTES This document addresses problems of a general nature. With respect to particular circumstances, local, state, and fede
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7、 the broad availability of proven, sound engineering and operating practices. This 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 w
8、ay to inhibit anyone from using any other practices. Classified areas may vary depending 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 operat
9、ions may differ. Users are solely responsible for assessing their specific equipment 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 Sta
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13、ying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API 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 iii API 579-2/ASME FFS-
14、2 2009 Fitness-For-Service Example Problem Manual FOREWORD The publication of the standard API 579-1/ASME 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 dama
15、ge. API 579-1/ASME FFS-1 was written to be used in conjunction with industrys existing codes for pressure 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 te
16、chnically sound consensus approaches that ensure the safety of plant personnel and the public while aging 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 pub
17、lication is provided to illustrate the calculations used in the assessment procedures in API 579-1/ASME FFS-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
18、word should indicates recommendations that are good practice but not essential. The word may indicates recommendations 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 encou
19、raged to inform the committee if they discover areas in which these procedures should be corrected, revised 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
20、, or SecretaryFFSasme.org. Items approved as errata to this edition are published on the ASME Web site under 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
21、be equivalent to that obtained by computer implementation, rounding of calculations should only be done on 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
22、 US Pressure Vessel- MAT calculation with PWHT 2 1 US Pressure Vessel- MAT calculation without PWHT3 1 US 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 Pressur
23、e VesselCylinder MAT reduction vs S*E*/SE (Stress Basis) 7 1 and 2US Pressure VesselSphereMAT reduction vs 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 Demethanize
24、r tower - Assessment based on fracture mechanics principlesof Part 9 Table E2-2 - Part 4 Examples on Assessment 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 msdInte
25、rnal pressure Full vacuumPoint thickness reading2 1 and 2US Pressure VesselCylinder Away from msdInternal pressureCritical thickness profiles 3 1 and 2SI Pressure VesselElliptical headAway from msdInternal pressureCritical thickness profiles 4 2 US Pressure VesselNozzleAt msd Internal pressureGiven
26、in the dataAPI 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual 2-2 Table E2-3 - Part 5 Examples 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 msdInt
27、ernal pressureLTA 2 1 and 2US Pressure VesselCylinder Away from msdInternal pressure2 Grooves3 2 US Pressure VesselCylinder Away from msdInternal pressure Supplementalloads LTA 4 2 US Pressure VesselCylinder Away from msdInternal pressureLTA 5 1 SI Pressure VesselCylinder Away from msdInternal press
28、ureLTA 6 2 US Pressure VesselNozzleAt msd Internal pressureUniform LTA7 1 US Storage Tank Cylinder Away from 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 Corro
29、sion ExampleAssessmentLevelUnitsType of Equipment Geometry Loading(s) Type of PittingComment1 1 US Pressure VesselCylinder Internal pressureWidespreadpitting - 2 1 SI PipingCylinder Internal pressureWidespreadpitting - 3 2 US Horizontal Pressure Vessel Cylinder Internal pressure Supplementalloads Wi
30、dely scattered pitting - 4 2 US Pressure VesselCylinder Internal pressureLocalized pittingLTA per Part 5 Level 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 F
31、FS-2 2009 Fitness-For-Service Example Problem Manual 2-3 Table E2-5 - Part 7 Examples on Assessment of Blisters 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 hydroge
32、n chargingservice2a1 Surface breakingCombined2bSub surface3 1 Surface breaking- 4 1 and 2Sub surfaceLevel 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
33、PeripheryCrown Cracking or VentingComment2 A 1 and 2OutsideNoCrack Level 2 per Part 5 Level 1B 1 OutsideNoVent - 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
34、Level 2 per Part 5 Level 1Note: Common characteristics: - Type of Equipment: Pressure Vessel- Geometry: Cylinder - 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
35、DistortionsExampleAssessment LevelUnitsType of Equipment Geometry Loading(s) Type of DamageComment1 1 and 2US PipingCylinder Internal pressureWeld misalignmentPeaking2 2 US PipingCylinder Fluctuating internal pressureWeld misalignment PeakingFatigue assessment by: - elastic stress analysis andequiva
36、lent stress - elastic stress analysis and structural stress3 1and 2US Pressure VesselCylinder Internal pressureOut-of-roundness Assessment based on Dmax-Dmin4 2 US Pressure VesselCylinder Internal pressureWeld misalignmentCenterline offset and peaking5 1 and 2US Pressure VesselCylinder Internal pres
37、sureOut-of-roundness Assessment based on radius expressedas a Fourier series 6 1 and 3US Pressure VesselShell - Heads - Stiffening ringsInternal pressure VacuumconditionsGeneral shelldistortionLevel 3 based on Finite Element Analysis: - limit load analysis (elastic perfectly plastic material behavio
38、r) - check oflocal strain (elastic-plastic with strain hardening material behavior) - elastic buckling analysis (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 o
39、f Crack-Like FlawsExampleAssessment LevelUnitsType of Equipment Geometry Loading(s) Type of Crack Comment1 1 US Pressure VesselCylinder Internal pressure- Longitudinal- Semi-elliptical Shallow crack in parallel to weld seam2 1 SI Pressure VesselSphereInternal pressure- Circumferential - Semi-ellipti
40、cal Deep crack perpendicular to weld seam3 1and 2US Pressure VesselCylinder Internal pressure- Semi-elliptical - 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
41、 be usedin assessment 5 1 and 2US Pressure VesselCylinder Internal pressure- Longitudinal- Semi-elliptical - Residual stressesdue to welding based on surface distribution- Uniform distribution alongthickness 6 1 and 2SI PipingCylinder Internal pressure Global bending moment- Circumferential - 360deg
42、ree crack - Residual stressesdue to welding based on through-thickness distribution- Fourth order polynomial along thickness7 2 SI PipingCylinder Internal pressure Global bending moment- Circumferential - Semi-elliptical - Residual stressesidentical to those of example 9.6- Coefficients of polynomia
43、lcalculated byweight functionmethod8 3 US Pressure VesselCylinder Internal pressure- Longitudinal- Semi-elliptical - Residual stressesidentical to those of example 9.5- Subcritical fatigue crack growth- Remaining life assessment 9 3 US - - - - Failure Assessment Diagram basedon actual material prope
44、rties10 3 SI Pressure VesselNozzle Internal pressure Quarter-ellipticalAssessment based on elastic-plastic 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 RangeExampleAsse
45、ssmentLevelUnitsType of Equipment Geometry Loading(s) Comment1 1 US Pressure VesselCylinder Elliptical headInternal 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 ath
46、igher temperature than designone- Calculation of overall damage in the complete expected life3 2 US HeaterTubes 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
47、in the creep range- Longitudinalsemi-elliptical surface crack - Creep crack growth- Calculation of remaining 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 a
48、fter 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 stress from hardness results 3 - Stress analysis for shell distortion- Testing and metallographic evaluation of material samples API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual
