FITNESS FOR SERVICE (FFS)

ON
NOZZLES WELD DEFECT

By :
Triwibowo
INDOCOR
Bandung : 17-September 2019
 I. Introduction
• Pressure vessels in an Oil and Gas Industry
are subjected to non destructive inspection by
using Phased Array Ultrasonics (PAUT). After
having been operated as long as 8 years, the
pressure vessel was inspected. Welding
defects propagated longer on the nozzle
weldments so that it is necessary to conduct
weld defects assessment.

• Hence, by considering ASME standard code

and API Recommended Practice 579 Fitness
for Services it is possible to take appropriate
measures for ensuring safe vessel operation.
II. FFS ACCORDING TO API 579
The longest weld defects on the nozzle of the following Vessel can be seen
in the enclosed inspection results.
The longest weld defect as long as 350 mm is modelled as following :

Amine Contactor Vessel

Nozzle weld defect inspection by means of PAUT
 ANOMALY REFLECTOR

Legend :
DA = Depth ( (distance from surface to reflector (flaw, indication))
PA = Surface Distance ( Horizontal distance from front probe wedge to reflector(flaw, indication)
SA = Sound Path (Angle Distance from Front wedge to reflector)
A% = Signal Amplitude (%)

Inspection Comments : Anomaly reflector detected from depth 21.30-33.47 mm , length 205
mm, suspected to intermittent lack of fusion and slag type of defect at
root /“double ½ v” area. Recommended observe this finding based
on related standard and regular inspect this area to monitor if any
growth of defect. Based on signal indication found and signal
analysis, no significant growth of defect at this area.
Crack area A
Nozzle is subjected to an operating pressure of 48 Bar. At the Incomplete
Fusion (IF) defect tip, the tensile stress is as high as 122.49 N/mm2 or
around 12.25 kg/mm2 (it is still lower than that of its allowable stress,
13.70 kg/mm2 at ambient temperature).
The ultimate strength of SA 516 Gr. 70 material is 485 – 620 MPA or about
48.5 - 62 kg/mm2 and the yield stress is 26.20 kg/mm2
III. DISCUSSION
The ultimate strength of SA 516 Gr. 70 material is
485 – 620 MPA or about 48.5 - 62 kg/mm2
The yield stress of SA 516 Gr. 70 material is 26.20
kg/mm2
The allowable stress of SA 516 Gr. 70 material is
13.70 kg/mm2
The FEM simulation of the existing Nozzle defect
shows that the stress at the weld defect tip is
12.25 kg/mm2. According to ASME II d, it is still
lower than that of the material allowable stress.
The weld defect model is conservative (array of
defects is representated as one long defect and the
defect tip is chosen to be sharp) so that margin
safety is ensured. Thus, the real value of the stress
at the defect tip is surely lower than 12.25
kg/mm2 because the real defect tip is blunt.

Moreover, the magnitude of the stress at the

defect tip from the FEM simulation as high as
12.25 kg/mm2 is on very small area only.
It is necessary to keep on the stainless steel
cladding (SS 316) staying intact so that no
sour gas and Amine can puncture the vessel
shell. Carbon steel of the vessel shell can be
attack by sour gas which is very corrosive
and further, Amine fluid might also induce
SCC.
It is also provided that the loading pattern of
the vessel is a constant pressure. In a such
situation, fatigue crack propagation is
unlikely.
Non destructive inspection by means of phased
array ultrasonics is carried out on the vicinity of
the Nozzles and the results are given in the
appendices. Any crack propagation as shown in the
periodic Non Destructive Inspection is very likely
caused by sour gas and Amine which might be
escaping through possible cladding degradation.
Hence, it is advisable to inspect the inner surface
cladding by means of Penetrant Test (PT) in the
next maintenance shut down.
Therefore, it can be concluded based on engineering
consideration that the pressure vessels containing these
weld defects under the normal operation parameter can
still be operated safely till the next maintenance / shut
down schedule whereas welding repair might be
conducted on the nozzles or on the cladding layer without
interrupting the production schedule. Nevertheless, clearly
at the moment the pressure vessel condition does not
meet the ASME requirement.

The analysis of the other nozzles containing defects are

similar and clearly those nozzles having smaller defect will
also be situated in the acceptable area.
In this diagram, the proximity to fracture is given on the vertical axis as the ratio
of applied stress intensity, K I, to fracture toughness, K mat:
K r = K I/K mat
If K r = 1, failure is predicted to occur by brittle fracture.
The proximity to plastic collapse is given by the ratio of the applied reference
stress, ref, to the yield strength Y.
L r = ref/ Y
If L r = L r max (see various cut-offs in Figure above) failure is predicted to occur by
plastic collapse.
• KMAT : material fracture toughness obtained
from literature or experiment (around 153.466
MPa√m)
•
• Toughness Ratio : Kr = (KI/KMAT) = (90.82
MPa√m) / (153.466 MPa√m) = 0.59
• Load Ratio : Lr = (122.49 MPa) / (262.0 MPa)
= 0.47
• Then, the Nozzle N1 having the longest defect
is plotted on the acceptable area (0.47, 0.59).
(0.47, 0.59)
 IV. CONCLUSION & RECOMMENDATION
The longest weld defect produces tensile stress as high
as 12.25 kg/mm2. It is still lower than that of the
allowable stress of the material SA 516 Gr. 70 ( 13.70
kg/mm2 ).
Hence, it can be concluded based on engineering
consideration that the pressure vessels containing all
these weld defects under the normal operation
parameter can still be operated relative safely till the
next 4 years (based on the existing crack propagation) so
that during the next maintenance (shut down) schedule
welding repair on the nozzles or on the cladding layer
might be conducted without interrupting the production
schedule.
 Continued .................................
The weld defect can propagate only if there
is dynamic loading till the stress intensity
factor reach its fracture toughness (KIc). If
there are no significant dynamic load and
corrosion attack act on the pressure vessel
(relatively constant load), then the vessel
will be relatively safe until the next shut
down / maintenance (in 4 years). Any local
break down on the SS 316 cladding layer, it
can induces corrosion attack caused by
sour gas as well as Stress Corrosion
Cracking (SCC) caused by Amine fluid.
 Continued .................................
For the sake of safety, periodic defect
measurement by using phased array
ultrasonics will be very usefull to measure
possible crack propagation and to predict
the remaining life of the vessel. Additional
infra red thermography can also be
considered for observing the possible
defect propagation. Usually, the vessel is
built under condition of leak before break
so that sudden fracture is unlikely. Stress
measurement and monitoring by means of
strain gauge might also be usefull.
THANK YOU