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PART 1 - INTRODUCTION
1.1 Introduction ........................................................................................................................... 1-2
1.2 Scope .................................................................................................................................... 1-2
1.3 Organization and Use ........................................................................................................... 1-4
1.4 Responsibilities ..................................................................................................................... 1-4
1.4.1 Owner-User.................................................................................................................... 1-4
1.4.2 Inspector ........................................................................................................................ 1-4
1.4.3 Engineer......................................................................................................................... 1-4
1.5 Qualifications......................................................................................................................... 1-5
1.5.1 Education and Experience ............................................................................................. 1-5
1.5.2 Owner-User.................................................................................................................... 1-5
1.5.3 Inspector ........................................................................................................................ 1-5
1.5.4 Engineer......................................................................................................................... 1-5
1.6 Definition of Terms ................................................................................................................ 1-5
1.7 References............................................................................................................................ 1-5
1.8 Tables ................................................................................................................................... 1-7
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3.7 In-Service Monitoring ..........................................................................................................3-14
3.8 Documentation ....................................................................................................................3-14
3.9 Nomenclature......................................................................................................................3-15
3.10 References..........................................................................................................................3-16
3.11 Tables and Figures .............................................................................................................3-17
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6.3 Data Requirements ............................................................................................................... 6-3
6.3.1 Original Equipment Design Data ................................................................................... 6-3
6.3.2 Maintenance and Operational History ...........................................................................6-3
6.3.3 Required Data/Measurements for a FFS Assessment .................................................. 6-4
6.3.4 Recommendation for Inspection Technique and Sizing Requirements......................... 6-5
6.4 Assessment Techniques and Acceptance Criteria ............................................................... 6-5
6.4.1 Overview ........................................................................................................................ 6-5
6.4.2 Level 1 Assessment.......................................................................................................6-6
6.4.3 Level 2 Assessment.......................................................................................................6-7
6.4.4 Level 3 Assessment.....................................................................................................6-11
6.5 Remaining Life Assessment ...............................................................................................6-12
6.6 Remediation ........................................................................................................................6-13
6.7 In Service Monitoring ..........................................................................................................6-13
6.8 Documentation ....................................................................................................................6-13
6.9 Nomenclature......................................................................................................................6-13
6.10 References..........................................................................................................................6-16
6.11 Tables and Figures .............................................................................................................6-17
vii
8.7 In-Service Monitoring ..........................................................................................................8-14
8.8 Nomenclature......................................................................................................................8-14
8.9 Documentation ....................................................................................................................8-17
8.10 References..........................................................................................................................8-18
8.11 Tables and Figures .............................................................................................................8-20
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10.5.7 Microstructural Approach ...........................................................................................10-29
10.6 Remediation ......................................................................................................................10-30
10.7 In Service Monitoring ........................................................................................................10-31
10.8 Documentation ..................................................................................................................10-31
10.9 Nomenclature....................................................................................................................10-32
10.10 Referenced Publications ...................................................................................................10-37
10.11 Tables and Figures ...........................................................................................................10-39
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13.3.2 Maintenance and Operational History .........................................................................13-3
13.3.3 Required Data/Measurements for a FFS Assessment ................................................13-3
13.3.4 Recommendations for Inspection Technique and Sizing Requirements.....................13-4
13.4 Assessment Techniques and Acceptance Criteria .............................................................13-4
13.4.1 Overview ......................................................................................................................13-4
13.4.2 Level 1 Assessment.....................................................................................................13-4
13.4.3 Level 2 Assessment.....................................................................................................13-6
13.4.4 Level 3 Assessment.....................................................................................................13-7
13.5 Remaining Life Assessment ...............................................................................................13-7
13.6 Remediation ........................................................................................................................13-7
13.7 In-Service Monitoring ..........................................................................................................13-7
13.8 Documentation ....................................................................................................................13-7
13.9 Nomenclature......................................................................................................................13-7
13.10 References..........................................................................................................................13-8
13.11 Tables and Figures .............................................................................................................13-9
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A.4.11 Nozzle Connections in Shells ..................................................................................... A-30
A.4.12 Junction Reinforcement Requirements at Conical Transitions................................... A-31
A.4.13 Other Components...................................................................................................... A-31
A.4.14 Allowable Compressive Stresses and Combined Loadings ....................................... A-31
A.5 Piping Components and Boiler Tubes ............................................................................... A-40
A.5.1 Overview ..................................................................................................................... A-40
A.5.2 Metal Loss................................................................................................................... A-40
A.5.3 Required Thickness and MAWP – Straight Pipes Subject To Internal Pressure ....... A-40
A.5.4 Required Thickness and MAWP – Boiler Tubes......................................................... A-41
A.5.5 Required Thickness and MAWP – Pipe Bends Subject To Internal Pressure .......... A-41
A.5.6 Required Thickness and MAWP for External Pressure.............................................. A-42
A.5.7 Branch Connections.................................................................................................... A-43
A.6 API 650 Storage Tanks...................................................................................................... A-43
A.6.1 Overview ..................................................................................................................... A-43
A.6.2 Metal Loss................................................................................................................... A-44
A.6.3 Required Thickness and MFH for Liquid Hydrostatic Loading ................................... A-44
A.7 Thickness Equations for Supplemental Loads................................................................... A-44
A.7.1 Overview ..................................................................................................................... A-44
A.7.2 Vertical Vessels Subject to Weight and Wind or Earthquake Loads .......................... A-44
A.7.3 Horizontal Vessels Subject to Weight Loads .............................................................. A-45
A.8 Nomenclature..................................................................................................................... A-45
A.9 References......................................................................................................................... A-55
A.10 Tables and Figures ............................................................................................................ A-56
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B1.7.5 Driving Force Method for Non-Growing Cracks........................................................ B1-33
B1.7.6 Assessment of Growing Cracks................................................................................ B1-34
B1.8 Definitions ........................................................................................................................ B1-34
B1.9 Nomenclature................................................................................................................... B1-37
B1.10 References....................................................................................................................... B1-43
B1.11 Tables .............................................................................................................................. B1-45
B1.12 Figures ............................................................................................................................. B1-57
Annex B4 - Alternative Plasticity Adjustment Factors And Effective Alternating Stress For
Elastic Fatigue Analysis
B4.1 Scope ................................................................................................................................. B4-2
B4.2 Definitions .......................................................................................................................... B4-2
B4.3 Effective Alternating Stress for Elastic Fatigue Analysis ................................................... B4-2
B4.4 Nomenclature..................................................................................................................... B4-6
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C.11 Stress Intensity Factor Solutions for Round Bars and Bolts.............................................. C-38
C.12 Stress Intensity Factor Solutions for Cracks at Fillet Welds .............................................. C-41
C.13 Stress Intensity Factor Solutions Cracks in Clad Plates and Shells.................................. C-43
C.14 The Weight Function Method for Surface Cracks.............................................................. C-43
C.15 Nomenclature..................................................................................................................... C-48
C.16 References......................................................................................................................... C-49
C.17 Tables and Figures ............................................................................................................ C-52
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F.4.1 General ..........................................................................................................................F-7
F.4.2 Fracture Toughness Parameters ...................................................................................F-8
F.4.3 Fracture Toughness Testing ..........................................................................................F-8
F.4.4 Lower Bound Fracture Toughness ..............................................................................F-11
F.4.5 Assessing Fracture Toughness from Charpy V-Notch Data........................................F-13
F.4.6 Fracture Toughness for Materials Subject to In-Service Degradation.........................F-17
F.4.7 Aging Effects on the Fracture Toughness of Cr-Mo Steels .........................................F-19
F.4.8 Fracture Toughness of Austenitic Stainless Steel .......................................................F-20
F.4.9 Probabilistic Fracture Toughness Distribution .............................................................F-20
F.4.10 Effect of Loading Rate on Toughness .........................................................................F-23
F.4.11 Sources of Fracture Toughness Data..........................................................................F-24
F.5 Material Data for Crack Growth Calculations......................................................................F-24
F.5.1 Categories of Crack Growth.........................................................................................F-24
F.5.2 Fatigue Crack Growth Equations.................................................................................F-26
F.5.3 Fatigue Crack Growth Data .........................................................................................F-29
F.5.4 Stress Corrosion Crack Growth Equations ..................................................................F-34
F.5.5 Stress Corrosion Crack Growth Data ..........................................................................F-35
F.6 Fatigue Curves....................................................................................................................F-35
F.6.1 General ........................................................................................................................F-35
F.6.2 Smooth Bar Fatigue Curves.........................................................................................F-35
F.6.3 Welded Joint Fatigue Curves.......................................................................................F-37
F.7 Material Data for Creep Analysis ........................................................................................F-38
F.7.1 Creep Rupture Time ....................................................................................................F-38
F.7.2 Tangent and Secant Modulus ......................................................................................F-39
F.7.3 Creep Strain-Rate Data ...............................................................................................F-40
F.7.4 Isochronous Stress-Strain Curves ...............................................................................F-40
F.7.5 Creep Regime Fatigue Curves (Crack Initiation) .........................................................F-40
F.7.6 Creep Crack Growth Data............................................................................................F-40
F.8 Nomenclature......................................................................................................................F-41
F.9 References..........................................................................................................................F-48
F.10 Tables and Figures .............................................................................................................F-55
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H.10 Assessment of Dents, Gouges, and Dent-Gouge Combinations ........................................ H-4
H.11 Assessment of Laminations ................................................................................................. H-4
H.12 References........................................................................................................................... H-4
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