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

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

Nozzle reinforcement, required area.

A1

available reinforcement area resulting from excess thickness in the shell.

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

available reinforcement area provided by a reinforcing pad.

A41

available reinforcement area provided by the nozzle to pad or nozzle to pipe attachment w

A42

available reinforcement area provided by the reinforcement pad attachment welds.

A43

available reinforcement area provided by the reinforcement pad.

B
cb
cn
cs

nozzle calculation parameter.

LOSSb + FCA.
LOSSn + FCAn.
LOSSs + FCAs.

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

current inside diameter of the nozzle including the specified FCA.

Dp

outside diameter of the reinforcing pad.

weld joint efficiency or quality factor from the original construction code, if unknown use 0

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.

FCAn nozzle future corrosion allowance.

FCAs shell future corrosion allowance.
fr1

strength reduction factor; fr1 = Sn /Sv for a set-in nozzle, fr1 =1.0 for a set-on nozzle.

fr2

strength reduction factor; fr2 = Sn /Sv.

fr3

strength reduction factor; fr3 = min [Sn , Sp]/Sv.

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

the inside nozzle projection.

IDs

inside diameter of shell including FCAs.

IRn

inside radius of nozzle (see also di)

IRs

inside radius of shell.

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).

inside diameter of nozzle including FCAn.

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

internal design pressure.

R
Rnc

inside radius corrected for LOSS and FCA as applicable.

S
Sn

allowable stress.

Sv

allowable stress for the vessel.

nozzle
tam

shell
tam

inside radius of nozzle corrected for LOSS and FCA as applicable.

allowable stress for the nozzle.
the average nozzle thickness in the nozzle reinforcement zone.
the average shell thickness in the nozzle reinforcement zone.

nominal or furnished thickness of the shell, the nominal or furnished pipe thickness adjust

tolerance, or cylinder thickness at a conical transition for a junction reinforcement calculat

te

nominal thickness of the reinforcing pad.

ti

nominal thickness of the of the internal projection of the nozzle wall.

tr

required thickness of the vessel wall computed with E = 1.0.

tn

furnished nozzle wall thickness.

tnom

nominal thickness of shell or nozzle.

trn

required thickness of a seamless nozzle wall.

tv

furnished vessel thickness.

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

weld leg size of the reinforcing pad-to-vessel attachment weld.

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

Dp
tn

2.5t or 2.5tn +te

Use smaller value

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

Use larger value

Use larger value

For nozzle wall inserted through the vessel

wall

For nozzle wall abutting the vessel

wall

Ar

Required reinforcement area

A1

Available reinforcement in the shell

A2

Available reinforcement in the nozzle

A3

Available reinforcement area, inside nozzle projection

A4 1

Available reinforcement area in the nozzle to pad or vessel weld

A4 2

Available reinforcement area in the nozzle to weld, inside surface

A4 3

Available reinforcement area in the reinforcing pad attachment weld

A5

Available reinforcement area in the reinforcing pad

Figure 1
Nozzle Parameters - Area Replacement Method

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

ABC-1234
Vessel

A Plant
Equipment:
Date:

Vessel Shell Design Data

Material
Allowable Stress (Sv)
Design Conditions (P)
Inside Diameter (IDs)
Inside Diameter (Ds)
Inside Radius (IRs)
Inside Radius (R)
Nominal Thickness (t) (tv)
Corrosion Allowance (FCAs)
Weld Joint Efficiency (E)

SA-516, Grade 70, year 1999

20000
psi
185
psig @ 400 F
60.000
in
60.250
in
30.000
in
30.125
in
0.600
in
0.125
in
1.0

LP Separator
5th September 2014
Note
s

Nozzle Design Data

Material
Allowable Stress (Sn)
Inside Diameter (IDn) (di)
Inside Diameter (Dn)
Inside Radius (IRn) (di)
Inside Radius (Rnc)
Nominal Thickness (tn)
Corrosion Allowance (FCAn)
Weld Joint Efficiency (E)
Nozzle Opening Efficiency (E1)
Reinforcing Pad Material
Nozzle Type (Set-On or Set-In)
Allowable Stress Re-pad (Sp)
Leg Length (wn)
Leg Length (wp)
Leg Length (wh)
Outside Diameter Re-pad (Dp)
Thickness Re-pad (te)

SA-105, year 1999

20000
psi
12.000
in
12.250
in
6.000
in
6.125
in
1.375
in
0.125
in
1.0
1.0
SA-516, Grade 70, year 1999
In
20000
psi
0.375
in
0.375
in
0.000
in
18.000
in
0.500
in
Inside nozzle projection (h)
0.000
in
Nom. T of inward projection (ti) 0.000
in

In or On
A41
A42
A43

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

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

Figure 2 - Nozzle Metal

Loss

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)

A Level 2 assessment is performed because the corrosion is at a major structural discontinuity (a

From the inspection data:

Notes
0.90 in

nozzle
am

shell
am

Required thickness of shell:

0.50 in

tr

0.281 in

PR

(Sv E 0.6P)

R IRs FCAs t

Required thickness of nozzle:

0.0614 in

PR
trn

(SnE 0.6P)

R IRn FCAn tn

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

Check the nozzle reinforcement; see API 579 Annex A.

LP Separator
5th September 2014

API 579-1 Refere

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

fr3 = min [Sn , Sp]/Sv =

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

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A1 =

max

A1 =

max

A1 =

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

{dc (E1 (t - cs) - Ftr) - B}

{2 (t + tn - cs - cn)(E1 (t - cs) - Ftr) - B}

A-16 (A.98)

1.2389 in2
0.2159 in2
1.239 in2
{5 (t - cs)(ti - 2cn) fr2}

A3 =

A3 =

min {5 (tn - 2cn)2 fr2}

{2h (ti - 2cn) fr2}

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

{5 (tn - cn - trn) fr2 (t - cs)}

{2 (tn - cn - trn)(2.5 (tn - cn) + te) fr2}

A2 =

min

A2 =

min

1.338 in2
3.479 in2

A2 =

min

A2 =

1.338 in2

(A.106)

A2 =

{5 (tn - cn - trn) fr2 (t {5 (tn - cn - trn) fr2 (tn

1.338
2.765
1.338

A41 w f
2
n r3

A42 wp2 fr4

A43 = (wh - cn)2 fr2 =

0.141 in2

(A.107)

0.141 in2

(A.108)

0.000 in2

(A.101)

A43 = (wh - cn)2 fr2 =

(A.109)

A5 =

A41 wn2 fr2

0.141
0.000

A42

0.000

A5 = [Dp - dc - 2(tn - cn)] te fr4

A5 =

1.625 in2

0.000

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

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

Total area replacement: ### in2

Total area replacement: ###

Does the nozzle have a reinforcing pad:

YES

Total area replacement for nozzle under consideratio

4.483 in2

Required area (Ar):

3.711 in2

Is area replacement required area (Ar):

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.

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

A Plant
Equipment:
Date:

ABC-1234
Vessel

LP Separator
5th September 2014

Appendix 1
Limitations

API 579-1 Refere

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

For vessels >60 in. diameter, MIN [D/3, 40 in.]

20 in

Vessel diameter:
Nozzle diameter:

60.000 in
12.000 in

Opening Limitations:
Does opening exceed limitations:

20 in
NO

API 579-1 Fitness-For Service Assessment

Plant ID
Equipment Number:
Equipment Type:

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.

om excess thickness in the nozzle or run pipe, as applicable.

om excess thickness in the nozzle internal projection or branch pipe,

y the welds and, for piping, the reinforcement pad.

y the nozzle to pad or nozzle to pipe attachment welds.

d length at the vessel wall mid-surface of a non-radial opening, in

the effects of metal loss and future corrosion allowance.

m the original construction code, if unknown use 0.7.

in a Category B butt joint, otherwise, the joint efficiency of the weld

he variation in internal pressure on different planes with respect to

be used for all configurations except that ASME VIII, Div 1, Figure
ced opeinings in cylindrical shells and cones.

Page 2
A Plant
5th September 2014

ds of operation equal to the nominal (or furnished thickness if

of operation equal to the nominal (or furnished thickness if

ell, the nominal or furnished pipe thickness adjusted for mill

cal transition for a junction reinforcement calculation, as applicable.

chment weld on the inside surface of the vessel.

ozzle-to-reinforcing pad (if a pad is used) attachment weld.

Page 3
A Plant
5th September 2014

te

ent area in the nozzle to weld, inside surface

ent area in the reinforcing pad attachment weld

Page 4
A Plant
5th September 2014

Page 5
A Plant
5th September 2014

e used in the assessment were determined by averaging thicknesses

API 579-1, paragraph 4.4.3.3.(b)(1) and Figure 4.9).

e corrosion is at a major structural discontinuity (a nozzle).

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

For nozzles without a reinforcing pad; A.3.11(a)(2)(ii):

{5 (tn - cn - trn) fr2 (t - cs)}
{5 (tn - cn - trn) fr2 (tn - cn)}
in2
in2
in2

(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

inal construction code is satisfied using the average

le reinforcement zone.

Page 9
A Plant
5th September 2014

Appendix 1
API 579-1 Reference

Page 10
A Plant
5th September 2014

Appendix 2

eraging - Nozzles and Fabricated Branch Connections

ne in the vertical direction on the inside of the shell.