Piping and pipeline assessment guide

573 Pages·2006·9.112 MB·English

by  Keith Escoe

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Piping and Pipeline
Assessment Guide
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Piping and
Pipeline
Assessment
Guide
A. Keith Escoe
AMSTERDAM • BOSTON • HEIDELBERG • LONDON
NEW YORK • OXFORD • PARIS • SAN DIEGO
SAN FRANCISCO • SINGAPORE • SYDNEY• TOKYO
Gulf Professional Publishing is an imprint of Elsevier
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Gulf Professional Publishing is an imprint of Elsevier
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Library of Congress Cataloging-in-Publication Data
Escoe,A. Keith.
Piping and pipeline assessment guide/Keith Escoe.—1st ed.
p. cm.—(Stationary equipment assessment series; v. 1)
Includes bibliographical references and index.
ISBN-13:978-0-7506-7880-3 (casebound :alk. paper)
ISBN-10:0-7506-7880-1 (casebound :alk. paper)
1. Piping—Maintenance and repair. 2. Pipelines—Maintenance and repair.
3. Service life (Engineering) I. Title. II. Series.
TJ930.E83 2006
621.8’672—dc22
2005027032
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library.
ISBN 13:978-0-7506-7880-3
ISBN 10:0-7506-7880-1
For information on all Gulf Professional Publishing publications
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This book is dedicated to my beloved wife,Emma. We have lived and seen
so much together!
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Contents
Preface xiii
1 An Introduction to In-plant Piping and Pipeline
Fitness-for-Service 1
Introduction 1
What Is Piping? 8
Areas Where Corrosion Attacks Piping 9
The Maximum Acceptable Operating Pressure (MAOP) 9
Assessment Procedure 14
Classification of Corroded Regions 15
External Versus Internal Corrosion 15
Localized Versus General Corrosion 15
Interaction of Closely Spaced Areas of Corrosion 16
Circumferential Extent of Damage 17
Welds,Elbows,and Branch Connections 17
Corroded Pit Region Interaction Parameters 18
Methodology 19
Determining the Allowable Length of Corrosion 26
Corrosion Allowance 27
Assessing Type 3 Flaws 28
Burst Test Validation 30
Circumferential Corrosion 31
Criteria for Circumferential Metal Loss 31
Methodology of Circumferential Metal Loss 33
Corrosion in Pipe Bends 35
Branch Connections and Fittings 37
Determining a Maximum Allowable Operating Pressure 37
Flaws in Heat Affected Zones of Welds 38
vii
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viii Contents
Example 1-1 39
Example 1-2 43
Checking for the Circumferential Direction Criteria 46
Example 1-3 47
2 An Introduction to Engineering Mechanics of Piping 50
Piping Criteria 51
Stress Categories 53
Allowable Stress Range for Secondary Stresses 53
Stresses Acting on Piping Elements 58
Stress Calculations 61
ASME B31.1 Code Stress 63
ASME B31.3 Code Stress 63
The Pipeline Codes—ASME B31.4 and B31.8 65
ASME B31.4—Liquid Transportation Pipelines Code 65
ASME B31.8—Gas Transmission and Distribution Pipeline Code 66
Flexibility and Stiffness of Piping 68
Stiffness and Large Piping 77
Flexibility Method of Piping Mechanics 78
Pipe Offsets and Loops 79
Pipe Restraints and Anchors 87
Criteria for Flexibility Analysis 90
Example Using the Empirical Flexibility Criterion 91
Suggested Criteria for Level of Piping Flexibility Analysis 96
Closure 98
3 Fitness-for-Service Topics of Local Thin Areas,
Plain Dents, Dents-Gouges, and Cracks for Piping 100
Useful RSF Equations Using API 579 105
Assessment Techniques and Acceptance Criteria 110
Remaining Life Assessment 110
Remediation 111
In-Service Monitoring 111
Documentation 111
Damage Mechanisms 112
Blisters and Laminations 115
Assessment of Local Thin Areas 116
General Metal Loss Assessment 117
Individual Point Readings 121
Thickness Profiles 121
Structural Discontinuities 122
Level 1 Part 4 Acceptance Criteria 126
Level 2 Assessments 127
Level 2 Part 4 Acceptance Criteria 128
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Contents ix
Local Metal Loss Assessment 129
Determining the LTA Boundary 132
Level 1 Part 5 Acceptance Criteria 133
Level 2 Part 5 Acceptance Criteria 138
Assessing Supplemental Loads 141
Level 3 Assessments 147
Elastic-Plastic Analysis of LTAs 148
Common Mistakes Made in Level 3 Assessments 152
Performing the Remaining Life Assessment 154
The MAWP Approach 154
The Thickness Approach 155
Material Property Data 157
Material Property Data Required for Assessment 157
Crack-like Flaws 169
Remediation of Crack Defects 177
Grooves,Plain Dents,and Dents with Gouges 179
Plain Dents 179
Dents and Gouge Combination Type Flaws 181
Example 3-1:API 579 Example 5.11.1 Revisited 184
Example 3-2:Dents and Gouge Combination Example 186
Example 3-3:Testing for General Metal Loss 189
Example 3-4:Surface Crack-Like Flaw in a Pipe 190
4 Fitness-for-Service for Brittle Fracture Concerns 201
Introduction 201
Brittle Fracture Concepts 203
Defect 203
Stress 204
Toughness 205
Definitions 208
Safe Operation at Low Temperatures Existing Equipment 209
Safe Operating Envelopes 209
Example 4-1:Determining the Basic MAT and Constructing the
MAT Curve 213
Determining the MAT Using Fracture Mechanics 217
Variations to MAT 218
Considering the Maximum Allowable Working Pressure 218
Material That Is Already Impact Tested 218
Pressure Reduction 219
Charpy Exemption Pitfalls—Words of Caution 219
Welding 220
Considerations for Design Codes Other Than ASME 220
Selecting Materials and Defining Impact Requirements—New Piping
andComponents 221
Use Good Quality Steel in the Base Case 222
Impact Test Temperature 222