Fitness-For-Service and Integrity of Piping, Vessels, and Tanks: ASME Code Simplified

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Fitness-For-Service and Integrity of Piping, Vessels, and Tanks: ASME Code Simplified

Fitness-For-Service and Integrity of Piping, Vessels, and Tanks: ASME Code Simplified

Authors: George Antaki

Published: 2005

ISBN: 9780071453998 0071453997

Contents

Preface

Chapter 1. Principles

1.1 What Is Fitness-for-Service?

1.2 FFS and Conduct of Operations

1.3 Fitness-for-Service of Old and New Equipment

1.4 Workmanship and FFS

1.5 FFS in Construction Codes

1.6 The Fitness-for-Service Step

1.7 Three Critical Questions

1.8 Maintenance Strategy

1.9 Pressure Boundary Integrity

1.10 The Five Disciplines

1.11 Regulatory Perspective

1.12 Codes, Standards, and Guides

1.13 Cum Laude

1.14 Technical Basis

1.15 Response Time

1.16 Summary

References

Chapter 2. Materials

2.1 Demand and Capacity

2.2 Material Groups

2.3 Ferrous Metals

2.4 Nonferrous Metals

2.5 Nonmetallic Materials

2.6 Basis for Material Selections

2.7 Mechanical Properties Overview

2.8 How to Achieve Desired Properties

2.9 Phase Diagram of Carbon Steel

2.10 Heat Treatment

2.11 Benefits of Postweld Heat Treatment

2.12 Types of Heat Treatment

2.13 Shop and Field Heat Treatment

2.14 The Larson–Miller Parameter

2.15 Heat and Lot

2.16 The Three Strength Parameters

2.17 Allowable Stress

2.18 Obtaining Strength Properties of Operating Equipment

2.19 Factors Affecting Strength Properties

2.20 Ductility

2.21 Ductile Fracture

2.22 Brittle Fracture

2.23 Toughness

2.24 Charpy Toughness

2.25 Fracture Toughness

2.26 Toughness Exemption Curve

2.27 Hardness

References

Chapter 3. Design

3.1 Basic Design and Detailed Design

3.2 Design Codes

3.3 Design Minimum Wall tmin

3.4 Future Corrosion Allowance FCA

3.5 Loads, Stresses, and Strains

3.6 Applied Loads and Residual Stresses

3.7 General Stresses

3.8 Example: Bending Stress

3.9 Pressure Stress

3.10 Pressure Stress Example

3.11 Wall Thickness Selection

3.12 Fossil Power Plant Example

3.13 Butt-Welded Fittings

3.14 Flanges

3.15 Socket and Threaded Fittings

3.16 Specialty Fittings and Components

3.17 Vessel Example

3.18 Design Principles

3.19 Design Pressure

3.20 Vessel Cylindrical Shell

3.21 Spherical or Hemispherical Head

3.22 Elliptical Head

3.23 Torispherical Head

3.24 Flat Head

3.25 Comparison

3.26 Plant Piping—ASME B31.3

3.27 Plant Piping Moment Stress

3.28 Applied Forces

3.29 Liquid Pipelines—ASME B31.4

3.30 Gas Pipelines

3.31 Fatigue

3.32 The ASME Boiler and Pressure Vessel Code Fatigue Method

3.33 The Markl Fatigue Method

3.34 Example of the Markl Method in Vibration

3.35 The Fracture Mechanics Fatigue Method

3.36 The AWS-AASHTO Fatigue Method

3.37 Fatigue Testing

3.38 ASME Stress Classification along a Line

3.39 External Pressure

References

Chapter 4. Fabrication

4.1 Fabrication and Construction Flaws

4.2 Base Metal Defects

4.3 Fabrication Flaws

4.4 Welding Techniques

4.5 Carbon Equivalent

4.6 Weld Quality

4.7 Welding in Service

4.8 Pressure or Leak Testing—How?

4.9 Pressure or Leak Testing—Why?

4.10 Pressure or Leak Testing—Cautions

4.11 Test Pressure for Tanks

4.12 Test Pressure for Pressure Vessels

4.13 Test Pressure for Power Piping

4.14 Test Pressure for Process Piping

4.15 Test Pressure for Liquid Pipelines

4.16 Test Pressure for Gas Pipelines

4.17 Mill and Handling Flaws

4.18 Field Weld Flaws

4.19 Weld Size

4.20 Residual Stress

4.21 Measuring Residual Stresses

4.22 Calculating Residual Stresses

4.23 Mechanical Joint Flaws

References

Chapter 5. Degradation

5.1 Corrosion

5.2 The Corrosion Engineer’s Perspective

5.3 The Facility Engineer’s Perspective

5.4 Damage

5.5 Degradation and Fitness-for-Service

5.6 Understanding Wall Thinning Mechanisms

5.7 The Electrochemical Cell

5.8 The Single Metal Electrochemical Cell

5.9 The Galvanic Cell

5.10 Concentration Cell

5.11 Size Effect

5.12 Parameters Affecting Corrosion Rate

5.13 Predicting Corrosion Rate—Is It Linear?

5.14 Predicting Corrosion Rate—Time in Service

5.15 Deposits and Tuberculation

5.16 General Corrosion

5.17 Galvanic Corrosion

5.18 Pitting

5.19 Crevice Corrosion

5.20 Corrosion under Insulation

5.21 Liquid-Line Corrosion

5.22 Microbial-Induced Corrosion

5.23 MIC Prevention

5.24 MIC Mitigation

5.25 Carbon Dioxide Corrosion

5.26 Erosion

5.27 Cavitation

5.28 Vapor-Liquid Erosion

5.29 Erosion in Gas-Liquid Service

5.30 Liquid Pipelines

5.31 Liquid-Sand Pipelines

5.32 Erosion-Corrosion

5.33 Environmental-Assisted Cracking Mechanisms

5.34 Corrosion Fatigue

5.35 Sensitized Stainless Steel

5.36 Sour Corrosion

5.37 Blisters and Cracks

5.38 High-Temperature Corrosion

5.39 Measuring Corrosion and Corrosion Rates

5.40 Coating

5.41 Common Coatings

5.42 Selection

5.43 Surface Preparation

5.44 Wrap Tape

5.45 Epoxy

5.46 Coal Tar Enamel

5.47 Heat-Shrinkable Sleeves

5.48 Multilayer Coating

5.49 Coating Performance

5.50 Coating Quality Control

5.51 Comparison

5.52 Practical Challenges

References

Chapter 6. Inspection

6.1 Principles of Inspection

6.2 Why?

6.3 What?

6.4 Where?

6.5 How?

6.6 When?

6.7 Risk-Based Inspection—What Is Risk?

6.8 A Number or a Matrix

6.9 The Objective of RBI

6.10 Necessary and Sufficient

6.11 Is RBI a Cost-Saving?

6.12 Qualitative or Quantitative RBI

6.13 RBI: A Seven-Step Process

6.14 Qualitative RBI

6.15 Example of Qualitative RBI—Steam Systems

6.16 Semiquantitative RBI—Likelihood

6.17 Semiquantitative RBI—Consequence

6.18 Fully Quantitative RBI—Likelihood

6.19 General Metal Loss Example

6.20 Limit State Function for a Crack

6.21 Crack Example

6.22 Likelihood Reduction Options

6.23 Correction for Reliability

6.24 Fully Quantitative Consequence

6.25 Advantages of Applying RBI

6.26 Cautions When Applying RBI

6.27 Integrity Programs for Pipelines

6.28 Overview of Inspection Techniques for Tanks, Vessels, and Pipes

6.29 Visual Examination (VT)

6.30 Magnetic Particle Testing (MT)

6.31 Liquid Penetrant Testing (PT)

6.32 Radiographic Testing (RT)

6.33 Ultrasonic Testing (UT)

6.34 Long-Range Guided Wave Ultrasonic Inspection

6.35 Eddy Current Testing

6.36 Magnetic Flux Leakage

6.37 Acoustic Emission Testing (AE)

6.38 Pig Inspections of Pipelines

6.39 Leak Detection Systems

6.40 Direct Assessment

References

Chapter 7. Thinning

7.1 Three Categories of Wall Thinning

7.2 Leak or Break

7.3 When Is Corrosion Considered General?

7.4 Principles of Evaluation for GML

7.5 Limitations

7.6 Buckling

7.7 Ultrasonic Grid

7.8 Storage Tank Example

7.9 API 653 Tank Thickness

7.10 Tank Fitness-for-Service—Level 1

7.11 Resolution

7.12 Tank Fitness-for-Service—Level 2

7.13 Power Plant Pipe Rupture

7.14 Power Pipe Fitness-for-Service—Level 1

7.15 Process Pipe Fitness-for-Service—Level 1

7.16 ASME B31G for Pipelines: What Is It?

7.17 Basis of ASME B31G

7.18 Derating a Pipeline

7.19 B31G Example for Gas Pipeline

7.20 Modified B31G

7.21 The RSTRENG® Method

7.22 The Remaining Strength Factor in B31G

7.23 Steam Condensate

7.24 The ASME VIII, Div.1, App. 32 Method

7.25 The ASME XI Code Case N-480 Method

7.26 Widespread Pitting

7.27 Localized Pitting

7.28 Example Pitting in Pipeline

7.29 Simple Criterion

References

Chapter 8. Geometric Defects

8.1 Integrity of Geometric Defects

8.2 Assessment Steps

8.3 Distorted Tank Bottom Example

8.4 Accidentally Bent Riser Example

8.5 Dents in Pipelines

8.6 Dents with Gouges

8.7 Wrinkles and Buckles

8.8 Mild Ripples

8.9 Blisters

8.10 Fitness-for-Service of Equipment with Blisters

8.11 Assessment of Weld Misalignment and Shell Distortions

8.12 Fitness-for-Service Assessment of Peaking

8.13 Deformed and Repaired Vessel Explosion

8.14 Defects Beyond Assessment

References

Chapter 9. Cracks

9.1 Cracklike Flaws

9.2 Crack Stability

9.3 Stress Intensity

9.4 Example—Crack in Pipeline

9.5 Stress Intensity Solutions

9.6 Fracture Toughness

9.7 Weld Residual Stresses

9.8 Ligament Reference Stress

9.9 Flow Stress

9.10 Foundation of Fracture Assessment, the FAD

9.11 The 15 Steps of Crack Analysis

9.12 Vessel Example

9.13 Margin to Failure

9.14 Leak Through Cracks

9.15 Application of Fracture Mechanics to Fatigue

References

Chapter 10. Creep Damage

10.1 What Is Creep?

10.2 High-Temperature Corrosion

10.3 The Difficulties of Creep Analysis and Predictions

10.4 Short- and Long-Term Overheating

10.5 Creep Assessment Methods

10.6 ASME III NH Method

10.7 Operating Loads

10.8 Time-Independent Material Properties

10.9 Time-Dependent Material Properties

10.10 Creep Life Analysis

10.11 Qualification

10.12 API 530 Creep Assessment

10.13 Nondestructive Assessment

10.14 High-Temperature B31.3 Pipe Application

10.15 Draft Method of API 579 Level 1

10.16 Life Fraction Analysis

10.17 Thinned Wall Remaining Life

10.18 Metallographic Life Assessment

References

Chapter 11. Overload

11.1 Overloads in Practice

11.2 Overpressure Allowance

11.3 Overpressure beyond Allowance

11.4 Key Considerations for Overpressure

11.5 Waterhammer Overload

11.6 Bolted Joint Failure

11.7 The Bullet Pig

11.8 Detonations and Deflagrations

11.9 Explosion Pressures

11.10 Explosion Damage

11.11 Example—Deflagration in Pipe

11.12 Material Strength at High Strain Rates

11.13 Explosive Rupture and Fragmentation

11.14 Effect of External Explosions

11.15 Natural Phenomena Hazards

11.16 Fitness-for-Service by Plastic or Collapse Analysis

11.17 Bending Failure

References

Chapter 12. Failure Analysis

12.1 Failure Mode and Effects

12.2 Root Cause Failure Analysis

12.3 Failure Analysis Tools

12.4 Leak-before-Break (LBB)

12.5 Stored Energy Associated with Flashing Liquids

12.6 Hydrotest Failure

12.7 Gas or Liquid Contents

12.8 The Tank Top Example

12.9 Tanks with Frangible Roof Design

12.10 Stored Energy

12.11 Leak-before-Break Using the Failure Assessment Diagram

References

Chapter 13. Repairs

13.1 Repair Work Package

13.2 Postconstruction Codes and Standards

13.3 Temporary or Permanent Repair?

13.4 Safety

13.5 Regulatory Requirements

13.6 Common Considerations for Materials

13.7 Common Considerations for Design

13.8 Common Considerations for Fabrication—Welding

13.9 Controlled Deposition Welding

13.10 Postconstruction Standards for Controlled Deposition

13.11 Common Considerations for Fabrication—Nonwelding

13.12 Common Considerations for Examination

13.13 Common Considerations for Testing

13.14 Common Considerations for Quality Control

13.15 Replacement

13.16 Flush Patch Repair

13.17 Example of Flush Patch Repair

13.18 Flaw Excavation

13.19 Example of Flaw Excavation Repair

13.20 Weld Overlay

13.21 Full Encirclement Welded Sleeve

13.22 Welded Leak Box

13.23 Fillet-Welded Patch

13.24 Mechanical Clamp

13.25 Inserted Liner

13.26 Pipe Splitting

13.27 Sacrificial Component

13.28 Nonmetallic Wrap

References

Appendix. WRC Bulletins

Index