2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

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SKG 12 Mechanical
SKG 15 Materials, Corrosion & Inspection Engineering
Level 3: Fitness-for-Service
Part 12: Plastic collapse assessment
1. Objective
2. Crack assessment framework
3. Exercises
4. Key lessons from Part 12
Outline
1. To practice some plastic collapse assessment calculations
Objective
1. Objective
2. Crack assessment framework
3. Exercises
4. Key lessons from Part 12
Outline
Crack assessment framework
Assessment of cracked component due to
combined action of 2 distinct failure modes
Plastic collapse Brittle fracture Failure mode
Limit load analysis Fracture mechanics
Analysis technique
Traditional: Applied pressure
API 579: Reference stress
K
I
= stress intensity factor
Applied load
Traditional: Limit load
API 579: Yield stress
K
IC
= fracture toughness
Component limitation
Failure Assessment Diagram
API 579: Yield stress
K
IC
= fracture toughness
Component limitation
Traditional: Applied pressure Limit load
API 579: Reference stress Yield stress
K
I
K
IC
Individual failure criterion
Combined failure criterion
1. Objective
2. Crack assessment framework
3. Exercises
4. Key lessons from Part 12
Outline
SA 285 C Carbon steel pressure vessel operating at 6 bar
Dimensions Material properties
Outside radius 3,500 mm Yield stress 207 MPa
Thickness 20 mm Ultimate stress 380 MPa
Axial through crack length 290 mm Fracture toughness 85 MPa(m)
0.5
Exercise 1: Based on limit load P
L
Based on the limit load approach, is the crack big enough to rupture the vessel?
What is the load ratio L
r
?
Note: P, P
L
= pressure
SA 285 C Carbon steel pressure vessel operating at 6 bar
Dimensions Material properties
Outside radius 3,500 mm Yield stress 207 MPa
Thickness 20 mm Ultimate stress 380 MPa
Axial through crack length 290 mm Fracture toughness 85 MPa(m)
0.5
Exercise 2: Based on reference stress
ref
Based on the reference stress approach, is the crack big enough to rupture the vessel?
What is the load ratio L
r
?
Note: P, P
L
= pressure
SA 285 C Carbon steel pressure vessel operating at 6 bar
Dimensions Material properties
Outside radius 3,500 mm Yield stress 207 MPa
Thickness 20 mm Ultimate stress 380 MPa
Circumferential through
crack length
410 mm Fracture toughness 85 MPa(m)
0.5
Exercise 3: Based on reference stress
ref
Based on the reference stress approach, is the crack big enough to rupture the vessel?
What is the load ratio L
r
?
Note: P, P
L
= pressure
SA 285 C Carbon steel pressure vessel operating at 6 bar
Dimensions Material properties
Outside radius 3,500 mm Yield stress 207 MPa
Thickness 20 mm Ultimate stress 380 MPa
Axial elliptical crack length 300 mm Fracture toughness 85 MPa(m)
0.5
Axial elliptical crack depth 12 mm
Exercise 4: Based on reference stress
ref
Based on the reference stress approach, is the crack big enough to rupture the vessel?
What is the load ratio L
r
?
Note: P, P
L
= pressure
SA 285 C Carbon steel pressure vessel operating at 6 bar
Dimensions Material properties
Outside radius 3,500 mm Yield stress 207 MPa
Thickness 20 mm Ultimate stress 380 MPa
Axial through crack length ?? mm Fracture toughness 85 MPa(m)
0.5
Exercise 5
What is the maximum size of the longitudinal crack that will rupture the vessel?
SA 285 C Carbon steel pressure vessel operating at 6 bar
Dimensions Material properties
Outside radius 3,500 mm Yield stress 207 MPa
Thickness 20 mm Ultimate stress 380 MPa
Circumferential through
crack length
?? mm Fracture toughness 85 MPa(m)
0.5
Exercise 6
What is the maximum size of the circumferential crack that will rupture the vessel?
Exercise 7
What can you conclude by comparing your answers from Exercises 5 & 6?
1. Objective
2. Crack assessment framework
3. Exercises
4. Key lessons from Part 12
Outline
Key lessons from Part 12
1. The highest load that a component can carry is called the limit load
2. When this load is reached, component will fail by plastic collapse
3. Formulas for limit load for most useful geometries are not readily available. Therefore use of
finite element method is required to determine limit load
4. API 579 uses the reference stress approach to determine the limit load
End of presentation
Thank you