API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

PART 4
ASSESSMENT OF GENERAL METAL LOSS
EXAMPLE PROBLEMS
4.1 Example Problem 1 ......................................................................................................... 4-1
4.2 Example Problem 2 ......................................................................................................... 4-6
4.3 Example Problem 3 ....................................................................................................... 4-10
4.4 Example Problem 4 ....................................................................................................... 4-14

4.1 Example Problem 1

Internal corrosion on the cylindrical shell of a heat exchanger has been found during an inspection. Details
regarding the heat exchanger and inspection data are given below. The heat exchanger was constructed to
the ASME B&PV Code, Section VIII, Division 1, Edition 1989. Determine if the heat exchanger is suitable for
continued operation.
Vessel Data
x Material = SA  516 Grade 60 Year 1989
x Design Conditions = 3.85 MPa @ 380q C and full vacuum @ 380q C
x Inside Diameter = 484 mm
x Nominal Thickness = 16 mm
x Future Corrosion Allowance = 2 mm
x Weld Joint Efficiency = 1.0
x Tubesheet to tubesheet distance = 1524 mm

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 API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

Inspection Data
Based on a visual inspection, the corrosion loss is characterized as general, and point thickness readings will
be used in the assessment (see paragraph 4.3.3.1 and 4.3.3.2). Point thickness readings were taken in
accordance with paragraph 4.3.3.2.
Table E4.1-1
Thickness Reading
Location t , mm
1 13
2 12
3 11
4 13
5 10
6 12
7 11
8 12
9 13
10 13
11 11
12 12
13 12
14 13
15 13

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 API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

Perform a Level 1 assessment for internal pressure per paragraph - 4.4.2

a) STEP 1 – Use the point thickness readings shown above; and determine the minimum measured
thickness, t mm , the average measured thickness, tam , and the Coefficient of Variation, COV. A template
for computing the COV is provided in Table 4.3 and is used in Table E4.1-2.

Table E4.1-2
Thickness Reading
Location trd ,i , i 1 to N trd , i  tam (trd ,i  tam ) 2
1 13 0.9333 0.8711
2 12 -0.0667 0.0044
3 11 -1.0667 1.1378
4 13 0.9333 0.8711
5 10 -2.0667 4.2711
6 12 -0.0667 0.0044
7 11 -1.0667 1.1378
8 12 -0.0667 0.0044
9 13 0.9333 0.8711
10 13 0.9333 0.8711
11 11 -1.0667 1.1378
12 12 -0.0667 0.0044
13 12 -0.0667 0.0044
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14 13 0.9333 0.8711
15 13 0.9333 0.8711
N N
1
tam
N
¦ trd ,i
i 1
12.0667 S ¦ (t
i 1
rd ,i  tam ) 2 12.9333
0.5
1 ª S º
COV 0.080
tam «¬ N  1 »¼
b) STEP 2 – The COV equals 8.0%, which is less than 10%; therefore, the average thickness to be used in
the calculation is the average thickness of the thickness distribution, or

tam 12.0667 mm

LOSS tnom  tam 16  12.0667 3.9333 mm

c) STEP 3 – Calculate the minimum required thickness (see Annex A).

c PR 3.85(242  2  3.9333)
tmin 10.1670 mm
 SE  0.6 P  96.196(1.0)  0.6(3.85)
L PR 3.85(242  2  3.9333)
tmin 4.9221 mm
 2SE  0.4 P  2(96.196)(1.0)  0.4(3.85)
tmin max ª¬tmin
c L
, tmin º¼ max[10.1670, 4.9221] 10.1670 mm
d) STEP 4 – Determine if the component is acceptable for continued operation.
Perform a Level 1 assessment using Table 4.4.

(tam  FCA 10.0667 mm) t (tmin 10.1670 mm) o False

Alternatively, the maximum allowable working pressure MAWP based on the average thickness ( tam ) can be
compared to the design pressure with the design pressure as the criterion.

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 API 579-2/ASME FFS-2 2009 Fitness-For-Service Example Problem Manual

t tam  FCA 10.0667 mm

MAWP
SEt  96.196 110.0667  3.813 MPa
R  FCA  LOSS  0.6t (242  2  3.9333)   0.6 10.0667 
3.813 MPa t 3.85 MPa o False
The Level 1 assessment criteria are not satisfied.
Perform a Level 2 assessment for internal pressure using Table 4.4.

(tam  FCA 10.0667 mm) t ( RSFa ˜ tmin  0.9 10.1287  9.1158 mm) o True

Alternatively, the maximum allowable working pressure ( MAWP ) based on the average thickness ( tam ) can
be compared to the design pressure with the design pressure as the criterion.
(tam  FCA) 10.0667
t 11.1852 mm
RSFa 0.9

MAWP
SEt  96.196 111.1852  4.225 MPa
R  FCA  LOSS  0.6t (242  2  3.9333)   0.6 11.1852 
4.225 MPa t 3.85 MPa o True
Check the minimum measured thickness criterion.
(tmm  FCA 8 mm) t max[0.5tmin 5.065, tlim ]
tlim max[0.2tnom  0.2 16  3.200, 2.500] 3.200 mm
8 mm t (max[5.065,3.200] 5.065 mm) o True
The minimum measured thickness criterion is satisfied.
The Level 2 assessment criteria for internal pressure are satisfied.

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