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Plant ID
Equipment Number:
Equipment Type:
ABC-1234
Vessel
A Plant
Equipment:
Date:
LP Separator
5th September 2014
Introduction
The following Level 2, Fitness-For-Service assessment was carried out on A Plant Production Plafo
1234, LP Separator, Nozzle: N-01, in accordance with API 579-1, Part 4, for Type 'B' pressurized c
subject to general metal loss resulting from internal corrosion, using the methods outlined in API
The assessement procedures are based on a thickness averaging approach. A Level 2 assesseme
performed because the corrosion is at a major structural disconitnuity, that is, at a nozzle.
Summary
The Level 2 assessment criteria are satisfied.
Nomenclature
Ar
A1
A2
available reinforcement area resulting from excess thickness in the nozzle or run pipe, as
A3
available reinforcement area resulting from excess thickness in the nozzle internal project
as applicable.
A4
available reinforcement area provided by the welds and, for piping, the reinforcement pad
A5
A41
available reinforcement area provided by the nozzle to pad or nozzle to pipe attachment w
A42
A43
B
cb
cn
cs
dc
diameter of the circular opening, or chord length at the vessel wall mid-surface of a non-ra
the plane under consideration including the effects of metal loss and future corrosion allow
di
Dp
E
E1
1.0 when the opening is in solid plate or in a Category B butt joint, otherwise, the joint effi
joint the nozzle intersects (see also ASME VIII, Div 1, UG-37 (a)).
correction factor that compensates for the variation in internal pressure on different plane
the axis of a vessel. A value of 1.00 shall be used for all configurations except that ASME V
UG-37 may be used for integrally reinforced opeinings in cylindrical shells and cones.
strength reduction factor; fr1 = Sn /Sv for a set-in nozzle, fr1 =1.0 for a set-on nozzle.
fr2
fr3
fr4
strength reduction factor; fr4 = Sp /Sv.
API 579-1 Fitness-For Service Assessment
Plant ID
Equipment Number:
Equipment Type:
ABC-1234
Vessel
A Plant
Equipment:
Date:
LP Separator
5th September 2014
Nomenclature
h
IDn
IDs
IRn
IRs
Ln
dimension to define the height of the reinforcement zone (see figure 2).
Lv
dimension to define the width of the reinforcement zone (see figure 2).
LOSSn metal loss in the nozzle from prior periods of operation equal to the nominal (or furnished
available) minus the minimum measured thickness at the time of the inspection.
LOSSs metal loss in the shell from prior periods of operation equal to the nominal (or furnished th
available) minus the minimum measured thickness at the time of the inspection.
P
R
Rnc
S
Sn
allowable stress.
Sv
nozzle
tam
shell
tam
nominal or furnished thickness of the shell, the nominal or furnished pipe thickness adjust
ti
tr
tn
tnom
trn
tv
wh
weld leg size of the nozzle-to-vessel attachment weld on the inside surface of the vessel.
wn
weld leg size of the nozzle-to-vessel or nozzle-to-reinforcing pad (if a pad is used) attachm
wp
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
Dp
tn
trn
Rnc
Cn
Include consideration of
these areas if Sn/Sv <
1.0
Ca
2.5t or 2.5tn
Use smallest value
tr
dc
dc or Rnc + tn + t
dc or Rnc + tn + t
Ar
A1
A2
A3
A4 1
A4 2
A4 3
A5
Figure 1
Nozzle Parameters - Area Replacement Method
ABC-1234
Vessel
A Plant
Equipment:
Date:
LP Separator
5th September 2014
Note
s
In or On
A41
A42
A43
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
Inspection Data
A sketch of the nozzle and metal loss are shown below.
CL
1.375"
Reinforcement Zone
0.375"
Lno
Metal Loss
0.60"
Reinforcing Pad
18" OD x 0.5"
Thick
Lv
The average nozzle thickness in the nozzle reinforcement zone is 0.9 in.
The corrosion is uniform for each inspection plane.
The thickness for the shell and nozzle to be used in the assessment were determined by ave
within the nozzle reinforcement zone (see API 579-1, paragraph 4.4.3.3.(b)(1) and Figure 4.9)
Notes
0.90 in
nozzle
am
shell
am
0.50 in
tr
0.281 in
PR
(Sv E 0.6P)
R IRs FCAs t
PR
trn
(SnE 0.6P)
R IRn FCAn tn
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
Required Area:
nozzle
dc IDn 2 tn tam
FCAn
dc =
F=
13.200 in
1
Nozzle Type =
Set-In
fr1 =
1.000
with
B 2 tn cn E1 (t cs ) Ftr
B=
A-16 (A.99)
r1
0.000
Ar dc tr F 2tntr F 1 fr1
Ar =
1 f
A-16 (A.97)
3.711 in
Available Area:
fr2 = Sn /Sv =
1.000
1.000
fr4 = Sp /Sv =
1.000
Cs =
Cn =
0.225 in
0.600 in
wn =
wp =
Dp =
te =
h=
0.375 in
0.375 in
18.000 in
0.500 in
0.000 in
A1 =
max
A1 =
max
A1 =
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
A-16 (A.98)
1.2389 in2
0.2159 in2
1.239 in2
{5 (t - cs)(ti - 2cn) fr2}
A3 =
A3 =
min
A3 =
-2.250 in2
0.153 in2
0.000 in2
A-16 (A.100)
N/A
0.000 in2
For nozzles with a reinforcing pad; A.3.11(a)(2)(iii): For nozzles without a reinforcing
A2 =
min
A2 =
min
A2 =
min
1.338 in2
3.479 in2
A2 =
min
A2 =
1.338 in2
(A.106)
A2 =
A41 w f
2
n r3
0.141 in2
(A.107)
0.141 in2
(A.108)
0.000 in2
(A.101)
(A.109)
A5 =
0.141
0.000
A42
0.000
1.625 in2
0.000
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
For nozzles with a reinforcing pad; A.3.11(a)(2)(iii): For nozzles without a reinforcing
Reinforcement Check:
Reinforcement Check:
A1 =
1.239 in2
A1 =
1.239
A2 =
1.338 in2
A2 =
1.338
A3 =
0.000 in
A3 =
0.000
A41 =
0.141 in
A41 =
0.141
A42 =
0.141 in
A42 =
0.000
A43 =
0.000 in2
A43 =
0.000
A5 =
1.625 in
A5 =
0.000
YES
4.483 in2
3.711 in2
YES
Analysis Results:
The area reinforcement calculation per the original construction code is satisfied using the avera
thicknesses for the shell and nozzle in the nozzle reinforcement zone.
The Level 2 assessment criterion is satisfied.
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
Appendix 1
Limitations
For openings in cylindrical shells, the opening does not exceed the following: A.3.11(a)(1)
For vessels 60 in. diameter, MIN [D/2, 20 in.
20 in
20 in
Vessel diameter:
Nozzle diameter:
60.000 in
12.000 in
Opening Limitations:
Does opening exceed limitations:
20 in
NO
A Plant
Equipment:
Date:
ABC-1234
Vessel
LP Separator
5th September 2014
Appendix 2
API 579-1, Figure 4.9, Zone for Thickness Averaging - Nozzles and Fabricated Branch Con
CL
Reinforciment
Zone
Nozzle
Reinforcing Pad
tn
Lno
te
di
tv
Lni
Lv
with
Lv
Shell
di =
tn =
tv =
te =
12.000 in
1.375 in
0.600 in
0.500 in
Lv = max [di, (di/2 + tn + tv)], thickness averaging zone in the horizontal direction.
Lno = min [2.5tv, (2.5tn + te)], thickness averaging zone in the vertical direction.
Lni = min [2.5tv, 2.5tn], thickness averaging zone in the vertical direction on the inside of the she
Lv =
Lno =
Lni =
12.0 in
1.5 in
1.5 in
Page 1
A Plant
5th September 2014
sment was carried out on A Plant Production Plaform, ABCe with API 579-1, Part 4, for Type 'B' pressurized components
ernal corrosion, using the methods outlined in API 579-2, 4.4.
ickness averaging approach. A Level 2 assessement was
structural disconitnuity, that is, at a nozzle.
Page 2
A Plant
5th September 2014
Page 3
A Plant
5th September 2014
te
Page 4
A Plant
5th September 2014
Page 5
A Plant
5th September 2014
shell
R IRs FCAs t tam
nozzle
R IRn FCAn tn tam
Page 6
A Plant
5th September 2014
API 579-1 Reference
Page 7
A Plant
5th September 2014
(A.103)
in2
(A.104)
in2
N/A
in2
(A.101)
in2
N/A
Page 8
A Plant
5th September 2014
For nozzles without a reinforcing pad; A.3.11(a)(2)(ii):
in2
in2
in2
in2
in2
in2
in2
in2
Page 9
A Plant
5th September 2014
Appendix 1
API 579-1 Reference
Page 10
A Plant
5th September 2014
Appendix 2