Section 6 - Stress Analysis in FFS Assessment

Fitness-for-Service (FFS) Assessment based on
API RP579
Section 6 - Stress Analysis in FFS Assessment
Copyright 2005, TWI Ltd 1
Copyright 2005, TWI Ltd World Centre for Materials Joining Technology World Centre for Materials Joining Technology
Stress Analysis for FFS
Assessment
Stress Analysis for FFS
Assessment
Introduction Introduction
Essential in a FFS assessment to know the Essential in a FFS assessment to know the
actual stresses applied to any damage: actual stresses applied to any damage:
What loads are applied? What loads are applied?
Manufacturing residual or direct stress? Manufacturing residual or direct stress?
Operation loads lower than design? Operation loads lower than design?
Linear elastic or elastic plastic? Linear elastic or elastic plastic?
Stress increase at local discontinuity? Stress increase at local discontinuity?
Determining stresses and strain ? Determining stresses and strain ?
In In- -situ measurement ? situ measurement ?
API RP579
Session agenda Session agenda
Definitions Definitions
Stress Stress- -strain response of materials strain response of materials
Stresses in pressure equipment Stresses in pressure equipment
Stresses in ASME PV and piping Stresses in ASME PV and piping
standards standards
Residual stresses Residual stresses
Finite element analysis Finite element analysis
Strain measurement Strain measurement
Stresses for a FFS assessment Stresses for a FFS assessment
Definition of stress Definition of stress
Stress: Internal force exerted by either of Stress: Internal force exerted by either of
two adjacent parts upon the other across two adjacent parts upon the other across
an imagined plane of separation. an imagined plane of separation.
The bar, subjected to tension, has been cut perpendicular to the The bar, subjected to tension, has been cut perpendicular to the axis axis
into two free bodies to show the normal stress, into two free bodies to show the normal stress,
x x
, This multiplied by , This multiplied by
the area (A) on which it acts must be in equilibrium with the ap the area (A) on which it acts must be in equilibrium with the applied plied
force (F) hence: force (F) hence:

x x
F F F F

x x
A = F A = F
x x
= F / A = F / A
API RP579
Definition stress terms Definition stress terms
Shear stress: when Shear stress: when
the force is parallel the force is parallel
to the plane to the plane
Normal stress: when Normal stress: when
the force is normal the force is normal
Compressive stress: Compressive stress:
when the normal when the normal
stress is directed stress is directed
toward the plane toward the plane
Tensile stress: when Tensile stress: when
the normal stress is the normal stress is
acting away from acting away from
the plane the plane
F F
F F
F F F F
90 90
o o
F F F F
90 90
o o
F F F F
90 90
o o
Definition stress terms Definition stress terms
Bending Bending
stress: when a stress: when a
bending bending
moment acts moment acts
normal to the normal to the
plane plane
Torsion stress: Torsion stress:
when a torque when a torque
acts parallel acts parallel
Point load on a beam Point load on a beam
Through beam bending stress Through beam bending stress
Tensile Tensile
Compressive Compressive
Solid cylinder with applied torque Solid cylinder with applied torque
Through cylinder torsion stress Through cylinder torsion stress
API RP579
Definition principal stresses Definition principal stresses
At a point in a stressed body there pass At a point in a stressed body there pass
3 mutually perpendicular planes, the 3 mutually perpendicular planes, the
stress on the planes are purely normal, stress on the planes are purely normal,
tension or compression. These are tension or compression. These are
termed the principal planes for that termed the principal planes for that
point. The stresses on the planes are point. The stresses on the planes are
principal stresses of which: principal stresses of which:
One is the maximum stress at the point ( One is the maximum stress at the point (
1 1
) )
One is the medium stress at the point ( One is the medium stress at the point (
2 2
) )
One is the minimum stress at the point ( One is the minimum stress at the point (
3 3
) )
Definition principal stresses Definition principal stresses

y y

y y

x x

x x

xy xy

xy xy

yx yx

yx yx

s s
= 0 = 0

1 1
or or
2 2
Element subjected to general two Element subjected to general two
dimensional stress system dimensional stress system
API RP579
Definition strain Definition strain
Strain: Any forced change in the Strain: Any forced change in the
dimensions of a body. A stretch is a dimensions of a body. A stretch is a
tensile strain; a shortening is a tensile strain; a shortening is a
compressive strain; and an angular compressive strain; and an angular
distortion is a shear strain. distortion is a shear strain.
Strain is generally used to denote unit Strain is generally used to denote unit
strain () strain ()
= = Change in length () Change in length ()
Original length (L) Original length (L)
As with stress there are principal As with stress there are principal
strains strains
Geometric stress concentrations Geometric stress concentrations
Stress concentration: Stress concentration:
Discontinuities of form may Discontinuities of form may
produce high localised stress produce high localised stress
Stress concentration factors Stress concentration factors
(SCF) have been developed (SCF) have been developed
to predict the stress at the to predict the stress at the
discontinuity discontinuity
Plate with a hole showing stress trajectories Plate with a hole showing stress trajectories
( )t d w = A
A
F
=
= K
0
0
nom
nom
max
t
-
API RP579
SCF example SCF example
Determine the maximum stress Determine the maximum stress
at a sphere/nozzle junction for at a sphere/nozzle junction for
a flush nozzle at the start and a flush nozzle at the start and
end of end of life. end of end of life.
Nozzle OD = 170mm Nozzle OD = 170mm
Nozzle thickness = 7.2mm Nozzle thickness = 7.2mm
Sphere OD = 2500mm Sphere OD = 2500mm
Sphere thickness = 57.15mm Sphere thickness = 57.15mm
Pressure = 40bar Pressure = 40bar
Future corrosion allowance = Future corrosion allowance =
2mm 2mm

max max
= s.c.f x (PR/(2T)) = s.c.f x (PR/(2T)) Maximum stress in sphere for internal pressure (flush nozzle) Maximum stress in sphere for internal pressure (flush nozzle)
Where, Where,
P = pressure (MPa) P = pressure (MPa)
R = mean radius of spherical shell (mm) R = mean radius of spherical shell (mm)
r = mean radius of nozzle (mm) r = mean radius of nozzle (mm)
t = wall thickness of nozzle (mm) t = wall thickness of nozzle (mm)
T = wall thickness of spherical shell (mm) T = wall thickness of spherical shell (mm)
Stress strain material response Stress strain material response
For most metallic For most metallic
materials at 0.002 materials at 0.002
strain (or a defined strain (or a defined
yielding point) the yielding point) the
material is no longer material is no longer
fully elastic and fully elastic and
starts to plastically starts to plastically
deform, which is deform, which is
none recoverable none recoverable
While in the elastic While in the elastic
region stress and region stress and
strain are strain are
proportional proportional
( (Hookes Hookes law) law)
API RP579
Stress strain material response Stress strain material response
The rate of change of The rate of change of
stress with respect to stress with respect to
strain in the elastic strain in the elastic
region is termed the region is termed the
modulus of elasticity modulus of elasticity
(or Youngs modulus) (or Youngs modulus)
and is denoted as E and is denoted as E
Most engineering Most engineering
design codes and design codes and
standards aim to limit standards aim to limit
the normal stress in a the normal stress in a
component to below component to below
yield levels. yield levels.
Ultimate tensile strength (UTS) Ultimate tensile strength (UTS)
Yielding criteria Yielding criteria
Real structures have Real structures have
complex stress complex stress
systems. systems.
A number of A number of
different yielding different yielding
criteria have been criteria have been
developed, the two developed, the two
most common are; most common are;
Tresca Tresca (maximum (maximum
shear stress) or Von shear stress) or Von- -
mises mises (shear strain (shear strain
energy) energy)
Yielding criteria envelope (2D) with Yielding criteria envelope (2D) with
actual test data actual test data
API RP579
Stresses in pressure equipment Stresses in pressure equipment
Stresses in pressure equipment are generally Stresses in pressure equipment are generally
produced from the following loads: produced from the following loads:
Internal and external pressure Internal and external pressure
Weight of equipment, including contents, live and Weight of equipment, including contents, live and
dead loads dead loads
Loads from attached equipment e.g. piping Loads from attached equipment e.g. piping
Attachment of internals (trays etc.), lugs, supports, Attachment of internals (trays etc.), lugs, supports,
skirts etc. skirts etc.
Temperature gradients and differential thermal Temperature gradients and differential thermal
expansion expansion
Wind, snow, seismic reactions Wind, snow, seismic reactions
Impact or shock loading Impact or shock loading
Pressure equipment stresses Pressure equipment stresses

C C

L L

R R
Circumferential Circumferential
stress ( stress (
C C
), also ), also
termed hoop termed hoop
Longitudinal stress Longitudinal stress
( (
L L
), also termed ), also termed
axial axial
Radial stress ( Radial stress (
R R
), in ), in
thin wall cylinders thin wall cylinders
this value is small this value is small
API RP579
Pressure equipment stresses Pressure equipment stresses
For the internal pressure only case for the For the internal pressure only case for the
circumferential (hoop) stress, in thinned circumferential (hoop) stress, in thinned
walled cylinders: walled cylinders:
The corresponding longitudinal (axial) stress The corresponding longitudinal (axial) stress
is: is:
Which is also the equation for a spherical Which is also the equation for a spherical
shell in both directions shell in both directions
P = pressure P = pressure
D = Outside diameter D = Outside diameter
t = wall thickness t = wall thickness
t 2
PD
=
h
t 4
PD
=
l
Pressure equipment design Pressure equipment design
Pressure equipment is usually designed Pressure equipment is usually designed
to construction standards requirements to construction standards requirements
by either: by either:
Design by rule (DBR): engineering formulas Design by rule (DBR): engineering formulas
to produce simple calculations to derive to produce simple calculations to derive
sizes etc. utilising an allowable standardised sizes etc. utilising an allowable standardised
design stress followed by strict adherence design stress followed by strict adherence
to specific rules. Does not provide the to specific rules. Does not provide the
designer with a value of the stress. designer with a value of the stress. This is
the philosophy of many national pressure
vessel design standards
Design by analysis (DBA): usually finite Design by analysis (DBA): usually finite
element analysis and stress categorisation element analysis and stress categorisation
API RP579
Pressure equipment DBA Pressure equipment DBA
Most of the design by analysis guidelines given Most of the design by analysis guidelines given
in the codes relates to design based on elastic in the codes relates to design based on elastic
analysis (1960s). analysis (1960s).
The rules were developed to guard against The rules were developed to guard against
elastic failure mechanisms. Thus guidelines elastic failure mechanisms. Thus guidelines
guard against three specific failure modes: guard against three specific failure modes:
gross plastic deformation, incremental plastic gross plastic deformation, incremental plastic
collapse ( collapse (ratchetting ratchetting) and fatigue. ) and fatigue.
In this approach the designer is required to In this approach the designer is required to
classify the stress into primary, secondary and classify the stress into primary, secondary and
peak categories and apply allowable stress peak categories and apply allowable stress
limits. limits.
See appendix B in API RP 579 See appendix B in API RP 579
ASME standards ASME standards
The most widely used standards in the The most widely used standards in the
world. world.
ASME section VIII division 1 Rules for ASME section VIII division 1 Rules for
the construction of pressure vessels the construction of pressure vessels
ASME section VIII division 2 ASME section VIII division 2
Alternative rules for the construction of Alternative rules for the construction of
pressure vessels pressure vessels
ASME B31.3 Process piping ASME B31.3 Process piping
API RP579
Cylindrical shell formulae (ASME) Cylindrical shell formulae (ASME)
S is the allowable stress for the S is the allowable stress for the
material material
E is the weld joint efficiency E is the weld joint efficiency
P is the internal pressure P is the internal pressure
R R
c c
is the internal radius adjusted for is the internal radius adjusted for
future corrosion future corrosion ect ect. .
t t
sl sl
is the extra material required for is the extra material required for
other loads (e.g. bending due to other loads (e.g. bending due to
wind) wind)
t t
min min
is the minimum required wall is the minimum required wall
thickness thickness
MWAP is the maximum allowable MWAP is the maximum allowable
wall thickness wall thickness

m m
is the nominal membrane stress is the nominal membrane stress
Formulae summarised in the Formulae summarised in the
appendix of API RP 579 for various appendix of API RP 579 for various
pressure equipment and sections pressure equipment and sections
Allowable stress (ASME) Allowable stress (ASME)
The maximum allowable stress value to be The maximum allowable stress value to be
used in any construction code is defined in the used in any construction code is defined in the
pressure vessel standard. pressure vessel standard.
For ASME VIII division 1 the listing of For ASME VIII division 1 the listing of
materials and allowable stress values are given materials and allowable stress values are given
in ASME section II, Part D in ASME section II, Part D
For the piping standard B31.3 the allowable For the piping standard B31.3 the allowable
stresses are given in its Appendix A stresses are given in its Appendix A
The allowable stresses are given for various The allowable stresses are given for various
temperatures temperatures
The materials are grouped by general alloying The materials are grouped by general alloying
content content
API RP579
Extract ASME II, Part D, Table 1A Extract ASME II, Part D, Table 1A
Important Important
Allowable stress basis (ASME) Allowable stress basis (ASME)
ASME VIII division 1 pre 1999 the allowable ASME VIII division 1 pre 1999 the allowable
room temperature stress was defined as: room temperature stress was defined as:
Minimum of 2/3 yield or of UTS Minimum of 2/3 yield or of UTS
ASME VIII division 1 post 1999 the allowable ASME VIII division 1 post 1999 the allowable
room temperature stress is defined as: room temperature stress is defined as:
Minimum of 2/3 yield or UTS/3.5 Minimum of 2/3 yield or UTS/3.5
ASME VIII division 2 the allowable room ASME VIII division 2 the allowable room
temperature stress is defined as: temperature stress is defined as:
Minimum of 2/3 yield or UTS/3 Minimum of 2/3 yield or UTS/3
API RP579
ASME joint efficiencies (E) ASME joint efficiencies (E)
Table UW Table UW- -12 in ASME VIII division 1, efficiencies based 12 in ASME VIII division 1, efficiencies based
on: on:
Joint type i.e. butt single or double sided Joint type i.e. butt single or double sided
Level of radiography i.e. 100%, spot or none Level of radiography i.e. 100%, spot or none
For example: For example:
A double V seam weld with 100% radiography E=1. A double V seam weld with 100% radiography E=1.
A double V seam weld with spot radiography E=0.85. A double V seam weld with spot radiography E=0.85.
Extract table UW-12 Extract table UW-12
API RP579
Example problem Example problem
Vessel has full radiography applied to all joints. Determine the Vessel has full radiography applied to all joints. Determine the
minimum require thickness for the shell. Material of constructio minimum require thickness for the shell. Material of construction n
is A516 grade 65 is A516 grade 65
Design pressure Design pressure
Design temperature Design temperature
Corrosion allowance Corrosion allowance
Residual stresses causes Residual stresses causes
Material Manufacture Material Manufacture
casting casting
forging forging
rolling rolling
heat treatments heat treatments
quenching quenching
straightening straightening
Fabrication Fabrication
cutting cutting
forming forming
bending bending
jigging, fit up jigging, fit up
welding welding
cladding cladding
PWHT PWHT
case hardening case hardening
machining machining
peaning peaning
auto auto frettage frettage
Service life Service life
proof load proof load
service load service load
service temperature service temperature
API RP579
Rolling & cooling residual stresses Rolling & cooling residual stresses
AC
Heating
furnace
slabs
4-High
Primary
leveler
Cooling bed Trimming
Discrete plate product
Reverse Mill Process
Thermal cooling controlled
Residual stresses due to welding Residual stresses due to welding
Tensile residual stresses in weld metal Tensile residual stresses in weld metal
are caused by the contraction of the are caused by the contraction of the
weld metal from softening temperature weld metal from softening temperature
The maximum residual stresses are The maximum residual stresses are
usually approximately equal to the yield usually approximately equal to the yield
strength strength if if there is restraint against there is restraint against
contraction and the contraction strain is contraction and the contraction strain is
greater than the yield strain greater than the yield strain
i.e. i.e. if if (T (T
s s
- -T T
0 0
) > ) >
y y
/E /E
API RP579
Typical residual stresses Typical residual stresses
Residual stresses in an Residual stresses in an as welded as welded thick section V thick section V- -butt butt
Standard residual stress profiles Standard residual stress profiles
BS 7910:1999 Amendment 1, BS 7910:1999 Amendment 1,
October 2000, Annex Q October 2000, Annex Q
R6 Revision 4, September 2000, R6 Revision 4, September 2000,
Chapter IV.4 Chapter IV.4
API 579, January 2000, Appendix E API 579, January 2000, Appendix E
API RP579
Finite Element Analysis Finite Element Analysis
The finite element method was first introduced The finite element method was first introduced
in the 1950 in the 1950 s s
It is a mathematical technique which models a It is a mathematical technique which models a
structure as thousands of small pieces structure as thousands of small pieces
(elements) (elements)
For each element, calculations can be For each element, calculations can be
performed simulating various loads to performed simulating various loads to
determine the structure's response (e.g. determine the structure's response (e.g.
deflection, strain, stress, etc.) deflection, strain, stress, etc.)
The technique requires large computational The technique requires large computational
resources, thus it has become more accessible resources, thus it has become more accessible
over the last twenty years. over the last twenty years.
Finite Element Analysis Finite Element Analysis
FEA shows results for FEA shows results for
whole structure whole structure
Strain measurement only Strain measurement only
provides the material provides the material
response at the surface response at the surface
location of measurement location of measurement
FEA only as good as the FEA only as good as the
analyst conducting the analyst conducting the
assessment (validation) assessment (validation)
Hand calculations Hand calculations
provide accurate results provide accurate results
but are typically useful but are typically useful
for only simple for only simple
geometries. geometries.
See appendix B of API RP See appendix B of API RP
579 for the use of FEA in 579 for the use of FEA in
a FFS a FFS
FEA results of a 2:1 elliptical head with FEA results of a 2:1 elliptical head with
nozzles, under pressure nozzles, under pressure
API RP579
While there are While there are
several methods of several methods of
measuring strain, the measuring strain, the
most common is with most common is with
a strain gauge a strain gauge
A stain gauges A stain gauges
electrical resistance electrical resistance
varies in proportion varies in proportion
to the amount of to the amount of
strain strain
Surface only stresses Surface only stresses
from the structure under from the structure under
assessment assessment
Limited number of Limited number of
readings readings
Can become detached Can become detached
Requires good bonding Requires good bonding
between the gauge and between the gauge and
structure structure
FEA and strain gauge FEA and strain gauge
combination excellent for combination excellent for
accurate determination accurate determination
of structure stresses of structure stresses
API RP579
Stresses required for FFS Stresses required for FFS
Depending on the assessment type, two Depending on the assessment type, two
components of stress may be required: components of stress may be required:
Primary stresses are developed by loads to Primary stresses are developed by loads to
satisfy the laws of equilibrium of external satisfy the laws of equilibrium of external
and internal forces and moments (e.g. and internal forces and moments (e.g.
pressure) pressure)
Secondary stress distribution is developed Secondary stress distribution is developed
by the constraint of adjacent parts or by by the constraint of adjacent parts or by
self self- -constraint of a structure (e.g. thermal constraint of a structure (e.g. thermal
expansion stresses) expansion stresses)
If it is uncertain whether a given stress is a If it is uncertain whether a given stress is a
primary or secondary stress, it is more primary or secondary stress, it is more
conservative to treat it as primary conservative to treat it as primary
Stresses required for FFS Stresses required for FFS
Stresses required for Stresses required for
assessment generally assessment generally
based on a damage type based on a damage type
Most complex is possibly Most complex is possibly
for crack for crack- -like flaws like flaws
The through wall stress The through wall stress
distribution is required distribution is required
to be known to be known
The distribution may be The distribution may be
linear (made up of linear (made up of
membrane and/or membrane and/or
bending distributions) or bending distributions) or
highly non highly non- -linear based linear based
on the component on the component
geometry and loading geometry and loading
conditions. conditions.
API RP579
Stresses required for crack-like flaws Stresses required for crack-like flaws
The stress distribution normal to the crack face The stress distribution normal to the crack face
should be determined for the primary, should be determined for the primary,
secondary, and residual loading conditions secondary, and residual loading conditions
based for an uncracked component based for an uncracked component
For linear stress distributions and less For linear stress distributions and less
complicated non complicated non- -linear stress distributions the linear stress distributions the
membrane and bending components can be membrane and bending components can be
found using the found using the linearisation linearisation process. process.
For highly non For highly non- -linear stress distributions API linear stress distributions API
579 appendix C gives a Fourth Order 579 appendix C gives a Fourth Order
Polynomial Stress Distribution method for Polynomial Stress Distribution method for
determining the membrane and bending determining the membrane and bending
components. components.
Stress linearisation Stress linearisation
Stress distribution Stress distribution
broken down into broken down into
membrane, bending membrane, bending
components components
Needed for both primary Needed for both primary
and secondary stresses and secondary stresses
Linearisation Linearisation can be over can be over
the cross section or just the cross section or just
the flaw, depends on the flaw, depends on
assessment type assessment type
Linearised Linearised membrane stress is: membrane stress is:

m m
= =
1 1
+ +
2 2
2 2
Linearized Linearized bending stress is: bending stress is:

b b
= =
1 1
- -
2 2
2 2
API RP579
Stress linearisation example Stress linearisation example
0
50
100
150
200
250
300
350
0 5 10 15 20 25 30 35 40 45
Distance through section, mm
P
e
r
p
e
n
d
i
c
u
l
a
r

s
t
r
e
s
s

t
o

f
l
a
w
,

M
P
a
Surface breaking flaw 10mm deep
310MPa at surface
100MPa at surface
Wall thickness of section 45mm
Linearise Linearise the stresses over the flaw the stresses over the flaw
The fourth order polynomial stress distribution The fourth order polynomial stress distribution
can be obtained by curve can be obtained by curve- -fitting the general fitting the general
stress distribution. The general form of the stress distribution. The general form of the
fourth order polynomial stress distribution is fourth order polynomial stress distribution is
as follows: as follows:
The equivalent membrane and bending stress The equivalent membrane and bending stress
distributions for the fourth order polynomial distributions for the fourth order polynomial
stress distribution are: stress distribution are:
Fourth Order Polynomial Stress
Distribution
Distribution
API RP579
Distribution
Distribution
Best fit 4th order polynomial equation
y = 1394.3x
4
+ 625.24x
3
- 2131.9x
2
- 22.318x + 240
-400
-300
-200
-100
0
100
200
300
0 0.2 0.4 0.6 0.8 1
Stress, MPa
D
i
s
t
a
n
c
e

t
h
r
o
u
g
h

w
a
l
l

(
x
/
t
)
Stress data Membrane Bending 4th Order polynominal
Stresses in FFS Stresses in FFS
Most level 3 assessment methods in API RP Most level 3 assessment methods in API RP
579 allow the use of a detailed stress analysis 579 allow the use of a detailed stress analysis
to determine the acceptability of the flaw to determine the acceptability of the flaw
The stress analysis techniques discussed in The stress analysis techniques discussed in
Appendix B of API RP 579 can be utilized Appendix B of API RP 579 can be utilized
FEA is typically used FEA is typically used
Handbook solutions may also be used if the Handbook solutions may also be used if the
solution is an exact match. solution is an exact match.
The evaluation based on a linear stress The evaluation based on a linear stress
analysis and stress categorization, or a non analysis and stress categorization, or a non- -
linear stress with plastic collapse. linear stress with plastic collapse.
Non Non- -linear stress analysis techniques are linear stress analysis techniques are
recommended, if data is available recommended, if data is available

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