4.

3 Reliable Assessment of Damages

Corrosion rate calculations Remaining life calculations

Inspection Data Quality - 1

Risk is increased when there is lack of, or uncertainty in the key information required to assess integrity. in, integrity Information on integrity of plant can be generated from the design, operational experience and inspection records, and from sound knowledge of the deterioration mechanisms and the rate at which deterioration will proceed. Inspections I i can then h be b planned l d at appropriate i intervals using inspection methods that are able to detect the type and level of deterioration anticipated in order to allow an assessment of the current and future fitness-for-service to be made.

N. Al-Khirdaji, AZTech Sr. Consultant

Inspection Data Quality - 2

Completeness and accuracy of inspection data are critical parameters in defining the condition of the inspected equipment or piping component/circuit. Such data will be used as the basis for determination of corrosion rates, remaining life, and in fitness-forservice assessments. The risk-based risk based approach, approach in particular particular, requires that the quality and veracity of the information is tested and validated.

Inspection Data Quality - 2

Audits of plant inspection records frequently id tif inconsistent identify i i t t or incorrect i t recorded d d measurements. Any such anomalies should be highlighted and investigated immediately so that they can be corrected (or verified if proven correct).

N. Al-Khirdaji, AZTech Sr. Consultant

Flaw Measurement Accuracy

The inspection methods selected must be capable of providing the required flaw information Inspection techniques used for flaw measurement may be different to inspection methods used for the detection of flaws. The selection of appropriate flaw measurement techniques may depend on the requirements of the applicable flaw acceptance standard.

TML (Thickness Measurement Location) Monitoring - 1

The minimum thickness at each TML can be located by ultrasonic scanning or radiography. radiography Electromagnetic techniques also can be used to identify thin areas that may then be measured by ultrasonics or radiography. When accomplished with UT, scanning consists of taking several thickness measurements at the TML searching for localized thinning. thinning The thinnest reading or an average of several measurement readings taken within the area of a test point shall be recorded and used to calculate corrosion rates, remaining life,

N. Al-Khirdaji, AZTech Sr. Consultant

TML (Thickness Measurement Location) Monitoring - 2

Where appropriate, appropriate thickness measurements should include measurements at each of the four quadrants on pipe and fittings, with special attention to the inside and outside radius of elbows and tees where corrosion/erosion could increase corrosion rates. As a minimum, the thinnest reading and its location shall be recorded.

TML (Thickness Measurement Location) Monitoring - 3

TMLs should be established for areas with continuing CUI corrosion at S/A interfaces CUI, interfaces, or other locations of potential localized corrosion as well as for general, uniform corrosion TMLs should be marked on inspection drawings and on the piping system to allow repetitive measurements at the same TMLs. TMLs This recording procedure provides data for more accurate corrosion rate determination

N. Al-Khirdaji, AZTech Sr. Consultant

Thickness Measurement Methods

When corrosion in a piping system is non-uniform or the remaining thickness is approaching the minimum required thickness, additional thickness measuring may be required. RT or UT are the preferred methods in such cases. Eddy current devices also may be used. When UT measurements are taken above 150 150F F (65C), instruments, couplants, and procedures should be used that will result in accurate measurements at the higher temperatures.

Thickness Measurement Methods

Inspectors should be aware of possible sources of f measurement inaccuracies i i and d make every effort to eliminate their occurrence. As a general rule, each of the NDE techniques will have practical limits with respect to accuracy

N. Al-Khirdaji, AZTech Sr. Consultant

Thickness Measurement Methods

Factors that can contribute to reduced accuracy of ultrasonic measurements include the following:
a. Improper instrument calibration. b. External coatings or scale. c. Excessive surface roughness. d. Excessive rocking of the probe (on the curved surface). e. Subsurface S b f material t i l flaws, fl such h as laminations. l i ti f. Temperature effects [at temperatures above 150F (65C)]. g. Small flaw detector screens. h. Thicknesses of less than 1/8 inch (3.2 mm) for typical digital thickness gauges.

Evaluating Inspection Data (PII RUNCOM Software)

RUNCOM: Corrosion Growth detected between successive inspections

N. Al-Khirdaji, AZTech Sr. Consultant

Remaining Life Determination

The remaining g life of the p piping p g system y shall be calculated from the following formula: Remaining life (years) = tactual - trequired
Corrosion rate

tactual = the actual thickness, in inches (mm), measured at the ti of time f inspection i ti for f a given i location l ti or component t trequired = the required thickness, in inches (mm), at the same location or component as the tactual measurement computed by the design formulas (e.g., pressure and structural) before corrosion allowance and manufacturers tolerance are added

Remaining Life Determination

The long long-term term (LT) corrosion rate of piping circuits shall be calculated from the following formula:
Corrosion Rate (LT) =

tinitial - tactual
Time (years) between tinitial and tactual

The short short-term term (ST) corrosion rate of piping circuits shall be calculated from the following formula:
Corrosion Rate (ST) =

tprevious - tactual
Time (years) between tprevious and tactual

N. Al-Khirdaji, AZTech Sr. Consultant

Remaining Life Determination

tinitial = the thickness, in inches (mm), at the same location as tactual measured at initial installation or at the commencement of a new corrosion rate environment tprevious = the thickness, in inches (mm), at the same location as tactual measured during one or more previous inspections.

The preceding formulas may be applied in a statistical approach to assess corrosion rates and remaining life calculations for the piping system. Care must be taken to ensure that the statistical treatment of data results reflects the actual condition of the various pipe components.

Remaining Life Determination

Statistical analysis employing point measurements is not applicable to piping systems with significant localized unpredictable corrosion mechanisms. Long-term and short-term corrosion rates should be compared to see which results in the shortest remaining life as part of the data assessment. The authorized inspector, inspector in consultation with a corrosion specialist, shall select the corrosion rate that best reflects the current process.

N. Al-Khirdaji, AZTech Sr. Consultant

Remaining Life Calculations - 3

The long term and short term corrosion rates should be compared and the higher value used in the remaining life calculations. If there is a significant difference between the two corrosion rates, further evaluations should be made in an attempt to determine the cause. The remaining life of the circuit should be based on the shortest calculated remaining life.

Corrosion Rate Estimation 1

Newly Installed Piping Systems or Changes in Service The expected corrosion rate must be estimated for new piping systems or for systems whose service has been changed. One of the following methods must be used to determine the probable corrosion rate.
Data collected from other piping systems fabricated of similar material and in comparable service. Estimate based on the owner-users experience or from published data for similar material in comparable service.

N. Al-Khirdaji, AZTech Sr. Consultant

Corrosion Rate Estimation 2

Newly Installed Piping Systems or Changes in Service Make initial thickness measurements after no more than three months of service service. Corrosion coupons or probes may be useful to help determine when thickness measurements should be made. Make additional thickness measurements as necessary until the corrosion rate is determined determined.

Corrosion Rate Determination Existing Piping Systems

Corrosion rates shall be calculated on either a short-term h tt or a long-term l t basis. b i If calculations indicate that an inaccurate rate of corrosion has been assumed, the rate to be used for the next period shall be adjusted to agree with the actual rate found

N. Al-Khirdaji, AZTech Sr. Consultant

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Maintenance Schedule Based on Crack Length vs. Fatigue Life Curves

Maintenance schedules can be developed from crack length vs. fatigue life (a-N a N) curves. curves Critical crack length acr is determined based on KIc and maximum design stress The time till repair is determined g an appropriate pp p factor considering of safety i.e., ar = acr/(FS). Remaining loading cycles before repair are determined from ai and ar acr
Catastrophic failure

ar ai

Repair needed Inspection Loading cycles, N

MAWP Determination - 1
The MAWP of a piping system must be determined based on the requirements of the applicable piping code (i.e., ASME B31.3 in the case of process plant piping systems). The MAWP of the system is that of the weakest component within the system. Thus, in addition to the pipe itself itself, all other system components must be considered (e.g., flanges, valves, etc.).

N. Al-Khirdaji, AZTech Sr. Consultant

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MAWP Determination - 2
Computations may be made for known materials if all the following essential details are known to comply with the principles of the applicable code:
a. Upper and/or lower temperature limits for specific materials. b Quality of materials and workmanship. b.Quality workmanship c. Inspection requirements. d.Reinforcement of openings. e. Any cyclical service requirements.

MAWP Determination - 3
If the pipe material is unknown, the MAWP calculations must be based on the lowest grade (i.e., (i e weakest) material and lowest weld joint efficiency that would be permitted by the code. When the MAWP is recalculated, the wall thickness used in these computations shall be the actual thickness as determined by y inspection p (see ( 5.6 for definition) minus twice the estimated corrosion loss before the date of the next inspection Examples 1 and 2 illustrate calculations of MAWP using the corrosion half-life concept.

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MAWP Determination - 4
Allowance shall be made for the other loadings i accordance in d with ith the th applicable li bl code. d The applicable code allowances for pressure and temperature variations from the MAWP are permitted provided all of the associated code criteria are satisfied.

Evaluation of Inspection Data

MAWP Calculations Using Corrosion Half-life Concept

Example 1:
Design Pressure: 500 psig (3104 kPa) Design Temperature: 400F (204oC) Pipe Material A 106 Gr. B Pipe Size: NPS 16 Allowable Stress: 20,000 psi (138 mPa) ( (from B31.3) g Weld Efficiency: y 1.0 ( (A 106 Gr. B is Longitudinal seamless pipe) Thickness Measured During Inspection: 0.32 in. (8.1 mm) Observed Corrosion Rate: 0.01 in./year (0.254 mm/yr) Next Planned Inspection: 5 years

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MAWP Calculations Using Corrosion Half-life Concept

Estimated thinning until next inspection = 5 x 0.01 = 0.05in. (5 x 0.254 = 1.27mm)

Evaluation of Inspection Data

MAWP = 2SEt/D (From ASME B31.3) = 2 x 20,000 x 1 x (0.32 2 x 0.05) /16 = 550 psig (3747 kPa ) Since the MAWP > 500 (system design pressure), the system may remain in service at the design pressure without repairs, replacements, or rerating.

Evaluation of Inspection Data

MAWP Calculations Using Corrosion Half-life Concept Example 2:
Ne t planned Next p a ed inspection spect o 7 yrs. y s. Estimated corrosion loss by date of next inspection = 7 X 0.01 = 0.07 in. (7 x 0.254 = 1.78mm)

MAWP = 2SEt/D = (2 x 20,000 x 1 x (0.32 2 x 0.07) /16) MAWP = 450 psig i (3104 kPa) kP ) Conclusion: Must reduce inspection interval or determine that normal operating pressure will not exceed this new MAWP during the 7th year, or renew the piping before the 7th year.

N. Al-Khirdaji, AZTech Sr. Consultant

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Illustrative Example Remaining Life Vs. Corrosion Rates and

Benefits of Conducting Repairs

N. Al-Khirdaji, AZTech Sr. Consultant

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MAWP Calculations Using Corrosion Half-life Concept

operation for 10 years and has been taken out of service for it first its fi t thorough th h inspection. i ti Pipe service - Gas with 3.5% H2S Minimum required thickness - 0.28 in. Originally installed thickness - 0.375 in. Thicknesses measured at five locations: 0.36, 0.32, 0.33, 0.34, 0.32 Required: Based on the information provided, calculate corrosion rate what maximum thickness measurement interval should be used for this system?

Evaluation of Inspection Data

Example 3: An NPS 16 piping system has been in

Evaluation of Inspection Data

Example 3 - Solution The pipe service places this system into Class I. Therefore the maximum interval cannot be more Therefore, than 5 years based only on the service. Now check the remaining life criterion. CRMax = (0.375- 0.32)/10 = 5.5 x 10-3 in./yr. Available corrosion allowance = (0.32 - 0.28) = 0.04 in. Maximum Interval = 0.04/(2 x 5.5 x 10-3 ) = 3.6 years < 5 years Maximum thickness measurement interval is 3.6 years.

N. Al-Khirdaji, AZTech Sr. Consultant

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Minimum Required Thickness Determination

The minimum required thickness of a piping system t (i.e., (i the th retirement ti t thickness) thi k ) must t be b determined considering all applicable design loads. The design pressure of the system will normally govern the minimum required thickness.
However, local loading g conditions (e.g., ( g wind or earthquake, valve weights, local thermal displacement stresses, etc.) might govern the minimum required thickness in particular situations. Both general and localized corrosion must be considered.

In cases where there are significant safety or economic loss consequences should a failure occur occur, it is prudent to increase the minimum required thickness above the calculated value.
This additional allowance is meant to account for unanticipated or unknown loads, undiscovered metal loss, tolerance in the thickness measurements, and resistance to normal abuse.

Minimum Required Thickness Determination - 2

In all cases, the normal code design formulas and allowable stresses must be used.

N. Al-Khirdaji, AZTech Sr. Consultant

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Assessment of Inspection Findings - 1

Pressure containing components found to have degradation that could affect their load carrying capability (pressure loads and other applicable loads, e.g., weight, wind, etc., per API RP 579) shall be evaluated for continued service. Fitness-for-service techniques, such as those documented in API RP 579, may be used for this evaluation. evaluation The fitness-for-service techniques used must be applicable to the specific degradation observed.

Reporting and Records for Piping System Inspection - 1

Any significant increase in corrosion rates shall h ll b be reported t d to t the th owner/user / for f appropriate action. The owner/user shall maintain appropriate permanent and progressive records of each piping system covered by API 570.

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Reporting and Records for Piping System Inspection - 2

These records shall contain pertinent data such as:
piping i i system t service; i classification; identification numbers; inspection intervals; and documents necessary to record the name of the individual performing the testing, the date, the types of testing, the results of thickness measurements and other tests, inspections, repairs (temporary and permanent), alterations, or rerating.

Reporting and Records for Piping System Inspection - 3

Design information and piping drawings may be included Information on maintenance activities and included. events affecting piping system integrity also should be included. The date and results of required external inspections shall be recorded. (See API RP 574 for guidance on piping inspection records records.) )

N. Al-Khirdaji, AZTech Sr. Consultant

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Weld Acceptance Criteria - 1

General As-welded As welded surface are typically permitted; The surface of the welds should be sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and valleys. The surfaces of the finished weld should be suitable to p permit proper p p interpretation p of radiographic g p and other required nondestructive examinations.

Weld Acceptance Criteria - 2

ASME B31.1 Visual examination consists of observation of whatever portions of a component or weld are exposed to such observation, either before, during or after manufacture, fabrication, assembly, or test.

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Weld Acceptance Criteria 3

ASME B31.1 The following indications are unacceptable:
cracks in external surface; undercut on surface which is greater than 1/32 in. deep; lack l k of f fusion f i on surface; f incomplete penetration (applies only when inside surface is readily accessible).

Reinforcement of Girth and Longitudinal Butt Welds

Maximum Thickness of Reinforcement for Design Temperature >750F 350-750F <350F Base Metal Thickness, in. in. in. Up to 1/8, inclusive 1/16 3/32 3/16 Over 1/8 to 3/16 1/16 1/8 3/16 Over 3/16 to 1/2 1/16 5/32 3/16 Over O 1/2 to t 1 3/32 3/16 3/16 Over 1 to 2 1/8 1/4 1/4 Over 2 5/32 * * * The greater of 1/4 in. or 1/8 x width of the weld, in.

N. Al-Khirdaji, AZTech Sr. Consultant

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ASME Section IX Rounded Indication Charts

ASME Section IX Rounded Indication Charts

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Fillet Weld Size B31.3

The size of an unequal leg fillet weld is the leg length of the largest inscribed isosceles right triangle (Theoretical Throat = 0.707 x Size)

Fillet Weld Size B31.3

The size of an unequal leg fillet weld is the leg length of the largest inscribed isosceles right triangle (Theoretical Throat = 0.707 x Size)

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Typical Details For Flange Attachment Welds B31.3

Figures (1) And (2) Slip-On Flange

Minimum Welding Dimensions SW Components B31.3

Socket Welding Components Other Than Flanges

N. Al-Khirdaji, AZTech Sr. Consultant

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Assessment of Inspection Findings

Pressure containing components found to have degradation that could affect their load carrying capability (pressure loads and other applicable loads, e.g., weight, wind, etc.,) shall be evaluated for continued service. Fitness-for-service techniques, such as those documented in API 579, may be used for this evaluation. evaluation The fitness-for-service techniques used must be applicable to the specific degradation observed.

Reporting and Records for Piping System Inspection - 1

Any significant increase in corrosion rates shall h ll b be reported t d to t the th owner/user / for f appropriate action. The owner/user shall maintain appropriate permanent and progressive records of each piping system covered by API 570.

N. Al-Khirdaji, AZTech Sr. Consultant

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Reporting and Records for Piping System Inspection - 2

These records shall contain pertinent data such as:
piping i i system t service; i classification; identification numbers; inspection intervals; and documents necessary to record the name of the individual performing the testing, the date, the types of testing, the results of thickness measurements and other tests, inspections, repairs (temporary and permanent), alterations, or rerating.

Reporting and Records for Piping System Inspection - 3

Design information and piping drawings may be included Information on maintenance activities and included. events affecting piping system integrity also should be included. The date and results of required external inspections shall be recorded. (See API RP 574 for guidance on piping inspection records records.) )

N. Al-Khirdaji, AZTech Sr. Consultant

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