Application of API 579-1/ASME FFS-1 FFS Methods to ASTs · -1/ASME FFS-1 Link . Other links in API 653 (direct and indirect) • 4.3.3.6: “…any thinning of the tank shell below

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Application of API 579-1/ASME FFS-1 FFS Methods to ASTs

Joel Andreani

NISTM 17th Annual International Aboveground

Storage Tank Conference

Orlando, Florida

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Presentation Outline/Objectives

API 579-1/ASME FFS-1 link to API 653 … and the FFS link to Mechanical Integrity (MI) and Life-Cycle Management (LCM)

Basics of API 579-1/ASME FFS-1…for Tanks: – What Tank Damage can you assess with API 579?

– What’s in API 579 that doesn’t apply to Tanks?

– What is the Basic FFS Process; What Data is needed for specific assessments; What Calculations are done, type of Results, and Follow-up Monitoring?

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Presentation Outline/Objectives What else will be covered: Basics of Brittle Fracture evaluation… Basics of FFS of Metal Loss Basics of FFS of Crack-like flaws & weld defects Basics of FFS of Distortion & Weld

Misalignment, FFS of Settlement Some types of Advance API 579 Analyses Examples Interspersed API 579 changes

coming

What’s NOT going to be covered? Details on the actual FFS calculations themselves

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FFS Fit to Mechanical Integrity and Life-Cycle Management (LCM)

LCM: From Design to Retirement (ASME PTB-3)

• In-service Inspection

• Damage/FFS • MI Req.: “Managing

Equipment Deficiencies”

• The 3 R’s…

Construction CodeASME VIII-1, VIII-2, VIII-3, B31.3

API 530, 620, 650

Commissioning (Baseline Inspection)

In-Service Inspection(Establish Inspection Interval)

• Prescriptive (API 510/570/653,NBIC)• Risk-Based (API 580/581,PCC3)

InspectionResults

Fitness-For-ServiceAPI 579/ASME FFS-1

Run/Rerate ReplaceRepair

ASME PCC2

Continue Service

Tech

nolo

gy In

tegr

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n

Anticipated Damage

Specify Design Conditions and Identify Damage Mechanisms(API 571 & WRC 489)

Select Materials of Construction

Identify Damage Mechanisms (API 571, WRC 488, WRC 489, WRC 490)

UnanticipatedDamage

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API 653 − API 579-1/ASME FFS-1 Link • API 653 Scope: “This standard recognizes fitness-

for-service assessment concepts for evaluating in-service degradation ... API 579-1/ASME FFS-1 provides detailed assessment procedures or acceptance criteria for specific types of degradation referenced in this standard. When this standard does not provide specific evaluation procedures or acceptance criteria…or when this standard explicitly allows the use of fitness-for-service criteria, API 579-1/ASME FFS-1 may be used …”

• API 579 Scope: “The methods and procedures in this Standard are intended to supplement and augment the requirements in API 510, API 570, API 653, and other post construction codes that reference FFS evaluations…”

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API 653 − API 579-1/ASME FFS-1 Link

Other links in API 653 (direct and indirect) • 4.3.3.6: “…any thinning of the tank shell below

minimum required…may be evaluated…by employing the design by analysis methods defined in Section VIII, Division 2, Appendix 4 of the ASME Code; or API 579-1/ASME FFS-1, Section 4, Section 5, or Section 6…”

• 4.3.5.3: “Shell distortions shall be evaluated…”

• 4.3.6: “Flaws such as cracks and laminations shall be thoroughly examined and evaluated…”

• 4.3.5.3: “The condition of the tank shell welds shall be evaluated for suitability for service using criteria from this standard, the as-built standard, or fitness-for-service assessment.”

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API 579-1/ASME FFS-1 Basics What can you assess with API 579-1 / ASME FFS-1?

Type of Assessment API 579 Part Applies to

Tanks Brittle Fracture 3 YES Metal Loss 4, 5, 6 YES Hydrogen Damage 7 N/A Distortion, Misalignment 8 YES Crack-like Flaws 9 YES Creep 10 N/A Fire Damage 11 YES Dents, Gouges 12 YES/NO Laminations 13 YES/NO Advanced Analyses Annex B YES Cop

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API 579-1/ASME FFS-1 Basics What’s the general process – 8 Steps, 3 Levels • STEP 1 – Damage identification (API 571) • STEP 2 – Limitations and Applicability • STEP 3 – Data Required • STEP 4 – Assessment Technique and

Acceptance Criteria • STEP 5 – Remaining Life Evaluation • STEP 6 – Remediation • STEP 7 – In-service Monitoring • STEP 8 – Documentation (part of MI programs) Added steps or omitted steps for a few analyses

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API 579-1/ASME FFS-1 Basics • LEVEL 1:

• Most conservative, screening criteria • Least information needed • Geared to plant inspection or engineering personnel

• LEVEL 2: • More precise and detailed, less conservative criteria • About the same information needed • Geared to engineering personnel or FFS specialists

• LEVEL 3: – • Most precise and detailed/analytical, least conservative • More detailed information needed • Intended to be done by FFS specialists Cop

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Brittle Fracture FFS Applied to Tanks What can you do in API 579-1/ASME FFS-1 Part 3?

• Supplement SFS Section 5 of API 653; done as part of Section 12 Hydrostatic Test Exemption

What data is needed?

• Material (toughness, YS, TS), Geometry, Operational History

• Inspection – any other damage present?

What calculations are done / What results? • Part 3 screening and Part 9 (Crack-like flaw) • Results: DMT; Hydrostatic Test Exempted?

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Brittle Fracture FFS Applied to Tanks Examples:

• Design Metal Temperature (evaluate adequate toughness)

• Hydrostatic Test Exemption

Critical Flaw Sizes

Stress Modeling

Doorsheet Addition

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Metal Loss FFS Applied to Tanks What can you do in API 579-1/ASME FFS-1?

• Supplement SFS Section 4 of API 653 • General (Part 4); Local (Part 5); Pitting (Part 6)

What data is needed?

• Material, Geometry, Operational History • Inspection – Thickness Grid, UT Scans, Pit data

What Calculations, Results, Monitoring?

• tmin, RSF (damage versus undamaged) or stress • FFS, Remaining Life, Re-rate the MFH • Monitor Corrosion Rate, FCA assumption

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Metal Loss FFS Applied to Tanks Data Results - Remaining Strength Factor (RSF):

DC UCa

RSFMFH = MFHRSF

Collapse Load, DamagedRSF =Collapse Load, Undamaged

M1 M2 M3 M4

Tank ShellLongitudinalWeld Seam

CircumferentialWeld Seam

Flaw

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Metal Loss FFS Applied to Tanks Example:

• General Corrosion & Unique Design • Level 3 (RSF or Stress Basis)

• tmin for future inspection • tmin for roof loads cleaning (weight)

Stress Results

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Flaw FFS Applied to Tanks What can you do in API 579-1/ASME FFS-1?

• Crack-Like Flaws, Weld Defects – Part 9 What data is needed?

• Material (YS, TS, KIC), Geometry, Operational History

• Inspection – Flaw Size/Location, other damage? What Calculations, Results, Monitoring?

• FAD Method, Critical Flaw Size(s): a vs. 2c • FFS, Remaining Life (Difficult) • Monitor flaw size, crack growth assumption

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Flaw FFS Applied to Tanks Data (flaw dimensions): Results - Failure Assessment Diagram (FAD):

Surface

Embedded

FAD

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Flaw FFS Applied to Tanks Example:

• Cracks in Ammonia Tank (Fit)

• Agricultural Tank weld Undercut (not Fit at MFH):

FAD

GOOD

NOT GOOD

FAD

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Distortion FFS Applied to Tanks What can you do in API 579-1/ASME FFS-1?

• Shell Distortion, Weld Misalignment – Part 8 What data is needed?

• Material (YS, TS, E), Geometry, Operational History • Inspection – Distortion mapped, other damage?

What Calculations, Results, Monitoring?

• RSF or stress approach, freq. Level 3 • FFS, Remaining Life (Not Practical) • Monitor – (No, except Settlement–related)

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Distortion FFS Applied to Tanks Data (measurements): Results – frequently use RSF

Misalignment

Out-of-Roundness

True Center ofMean Circle

Center ofMeasurement

RB1

A1

15°

30°

45°

θ0°

1 23

4

5

6

7

8

9

1011121314

15

16

17

18

19

20

21

22

23

24R1 R2

R3

R4

Local Deformation

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Distortion FFS Applied to Tanks Example:

• Shell Distortion resulting from Settlement

• RSF Results with Wind, EQ (not Fit):

Failure Assessment

Diagram (FAD)

FEA Model of Tank

Undistorted Tank Distorted TankNorth 4.838 5.405 1.12East 4.839 3.681 0.76

South 4.937 5.006 1.01West 4.838 4.950 1.02North 0.631 0.624 0.99East 0.627 0.643 1.03

South 0.631 0.587 0.93West 0.631 0.522 0.83

Load Case RSFFirst Eigenvalue

Wind

Seismic

RSF of 0.90 Required

Distorted Tank

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Advance Analysis Applied to Tanks What can you do in API 579-1/ASME FFS-1?

• Annex B: Settlement, design issues, damage due to significant events – Blast, EQ, etc.

What data is needed? • Material (YS, TS, E), Geometry, Operational

History, Event History • Inspection – Varies by damage

What Calculations, Results, Monitoring?

• RSF or stress approach, ALL Level 3 • FFS, Remaining Life (Not Practical) • Monitor (Not Practical)

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Advanced Analysis FFS Applied to Tanks Examples:

• Blast Event nearby (double-walled tank):

Results

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Advanced Analysis FFS Applied to Tanks Examples:

• Damage to anchor area of unique design (double bottom with grating):

Results

Models

Design Copyri

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API 579-1/ASME FFS-1 Changes API 579-1/ASME FFS-1 – 2015 (expected this Fall):

• Annex A (Code Calculations) moved to Part 2 • Thinning: Introduced two CA’s (within thinned

region and outside of thinned region) • Part 4 changes to thickness averaging • New Part 5 Level 1 Local Thinning Procedure • Improvements to Part 9 Crack-like flaws:

• No PSF for Level 2 any longer • Moved Annex C, D, E and part of F in Part 9 • Changes to Toughness and Residual Stress

• NEW Part 14: Fatigue

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