PART 4 – ASSESSMENT OF GENERAL

METAL LOSS
Level 1 Assessment
4.4.2.1 The following assessment procedure shall be used to evaluate Type A Components.

a) STEP 1 – Take the point thickness reading data in accordance with paragraph 4.3.3.2. From this data
determine the minimum measured thickness, t mm , the average measured thickness, t am , and the
Coefficient Of Variation (COV).

b) STEP 2 – If the COV from STEP 1 is less than or equal to 0.1, then proceed to STEP 3 to complete the
assessment using the average thickness, t am . If the COV is greater than 0.1 then the use of thickness
profiles should be considered for the assessment.

c) STEP 3 – The acceptability of the component for continued operation can be established using the
Level1 criteria in Table 4.4, Table 4.5, Table 4.6, and Table 4.7. The averaged measured thickness or
MAWP acceptance criterion may be used. In either case, the minimum thickness criterion shall be
satisfied. For MAWP acceptance criterion to determine the acceptability of the equipment for continued
operation.
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
• Material = SA−516 Grade 60 Year 1989
• Design Conditions = 3.85 MPa @380° C and full vacuum @380° C
• Inside Diameter = 484mm
• Nominal Thickness = 16mm
• Future Corrosion Allowance (FCA) = 2mm Location Thickness Reading t,mm
• Weld Joint Efficiency = 1.0
1 13
• Tubesheet to tubesheet distance = 1524mm
2 12
3 11
Inspection Data 4 7
Based on a visual inspection, the corrosion loss is characterized as general, and
5 10
point thickness readings will be used in the assessment. Point thickness
readings were taken in accordance with API 579. 6 12
7 11
8 12
4.2.5 Definition of Component Types 9 9
Type B, Class 1 components 10 13
11 11
12 12
13 12
14 4
15 13
 Inspection Data
Based on a visual inspection, the corrosion loss is characterized as general, and point thickness readings will
be used in the assessment. Point thickness readings were taken in accordance with API 579.

Location Thickness Reading t,mm

1 13
2 12
3 11
4 7
5 10
6 12
7 11
8 12
4.3.3.2 If point thickness readings are used in the assessment, the 9 9
assumption of uniform metal loss should be confirmed.
10 13
 A minimum of 15 thickness readings should be used unless the level of NDE
utilized can be used to confirm that the metal loss is general . 11 11
 If the Coefficient Of Variation (COV) of the thickness readings is greater than
12 12
10%, then thickness profiles shall be considered for use in the assessment. 13 12
The COV is defined as the standard deviation divided by the average.
14 4
15 13
4.3.3.2 If the Coefficient Of Variation (COV) of the thickness readings is greater than 10%, then thickness profiles shall be
considered for use in the assessment. The COV is defined as the standard deviation divided by the average.

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

therefore, the average thickness to be

=8% used in the calculation is the average
thickness of the thickness distribution
c) STEP 3 – The acceptability of the component for continued operation can be established using the Level1 criteria in Table 4.4, Table
4.5, Table 4.6, and Table 4.7. The averaged measured thickness or MAWP acceptance criterion may be used. In either case, the
minimum thickness criterion shall be satisfied. For MAWP acceptance criterion to determine the acceptability of the equipment for
continued operation.
Calculate the minimum required thickness (see Annex 2C.3.3).

d) STEP 4 – Determine if the component is acceptable for continued

operation. Perform a Level 1 assessment using Table 4.4.

  12.0667-2= 10,0667mm
Alternatively, the maximum allowable working pressure MAWP based on the average thickness (t am) can be
compared to the design pressure with the design pressure as the criterion

Perform
  a Level 2 assessment for internal pressure using Table 4.4 Acceptance criteria.
Determine

  12.0667-2= 10,0667mm

  =9,12788215

  =4,43336645

  = 10,06667mm →True

The Level 2 assessment criteria for internal pressure are satisfied.

4.3.3.3 Procedure to determine the required inspection locations and the Critical Thickness
Profiles (CTPs).

a) STEP 1 – Locate the region of metal loss in the component and determine the location,
orientation, and length of the inspection plane(s).

b) STEP 2 – To determine the inspection plane(s) for thickness readings the following shall be
considered:
1) Pressure Vessel Heads and Spheres – Both the circumferential and meridional
directions shall be set as inspection plane(s).

2) Cylindrical Shells, Conical Shells and Elbows – The critical inspection plane(s) are
meridional (longitudinal) if the circumferential stress due to pressure governs, and
circumferential if the longitudinal stress due to pressure and supplemental loads
governs (see Figure 4.8).
c) STEP 3 – Mark each inspection plane on the component; the length of the inspection plane
for the corroded/eroded region should be sufficient to characterize the metal loss.

d) STEP 4 – Determine the uniform thickness away from the local metal loss at the time of the
assessment, trd .
e) STEP 5 – Measure and record the wall thickness readings at intervals along each
inspection plane and determine the minimum measured wall thickness, tmm . The spacing
distance for thickness readings should allow for an accurate characterization of the thickness
profile.

1.- If the corroded surface is not accessible for visual inspection, then the recommended
spacing distance for thickness readings along each inspection plane, Ls , is given by
Equation (4.1); however, a minimum of five thickness readings is recommended for each
inspection plane(s).

The length for thickness averaging L is computed using Equation (4.6).

Example Problem 2
Internal corrosion at a longitudinal weld seam in a pressure vessel has been found during an inspection. Details regarding the pressure vessel
and inspection data are given below. The vessel was constructed to the ASME B&PV Code, Section VIII, Division 1, Edition 1998 with the 1999
Addenda. Evaluate if the vessel shell
is fit-for-service.

a)
  STEP 1 – Determine the thickness profile data in
accordance with paragraph 4.3.3.3 and determine the
minimum measured thickness, .
b) STEP 2 – Determine the wall thickness and diameter to be used in the
assessment using Equation (4.2) and Equation (4.3) or Equation (4.4).

=0,650 in
 
D
 

  c) STEP 3 – Compute the remaining thickness ratio, .

  =0,4

Thickness
  profiles are provided, the
data for thickness readings
is in the above table

d) STEP 4 – Compute the length for thickness averaging, L where the parameter Q is
evaluated using Table 4.8
  L=2,564
STEP
  5 – Establish the Critical Thickness Profiles (CTP’s) from the thickness profile data (see paragraph 4.3.3.3). Determine the average measured
thickness , based on the longitudinal CTP and the average measured thickness based on the circumferential CTP. The average measured
thicknesses , and shall be based on the length L determined in STEP 4 (see Figure 4.19). The length L shall be located on the respective CTP such
that the resulting average thickness is a minimum.
f)
  STEP 6 – Based on the values of , and from STEP 5, determine
the acceptability of the component for continued operation using the
Level 1 criteria in Table 4.4, Table 4.5, Table 4.6, and Table 4.7, as
applicable.

The averaged measured thickness or MAWP acceptance criterion

may be used. In either case, the minimum measured thickness, ,
shall satisfy the criterion in Table 4.4, Table 4.5, Table 4.6 and Table
4.7.

For MAWP acceptance criterion (see Part 2, paragraph 2.4.2.2.e) to

determine the acceptability of the equipment for continued operation.

The minimum thickness criteria are satisfied.

The Level 1 assessment criteria are not satisfied.
The Level 1 assessment criteria are not satisfied due to the average measured thickness in the longitudinal CTP.
Check the minimum thickness criteria in Table 4.4

The minimum thickness criteria are satisfied. The Level 1 assessment criteria are not satisfied.
Perform a Level 2 Assessment using Table 4.4

  =0,37915161

  =0,19077636

0,3,26
  ≥ 0,379 →False
0,326
  ≥ 0,190
The Level 2 Assessment criteria are not satisfied.