A Methodology to Assess Elbow Fittings With Localized Material Variations

Elbow fittings are manufactured using quenching and tempering heat treatment processes. Such fittings can occasionally exhibit localized regions with lower yield strength than the design target, potentially due to non-uniform heat treatment. This paper presents an analytical methodology to examine the influence of these localized lower yield zones on the load capacity of the affected pipe fitting. In parallel, full-scale testing has been performed to quantify the actual response of the elbows under a combination of different loading conditions. The experimental data is used to validate the analytical approach. Details of the analytical method include a two-fold criterion: a global failure based on elastic–plastic stress analysis and a local failure based on the tri-axial strain limit per ASME Boiler and Pressure Vessel Code Section VIII, Division 2. This paper presents the details of the finite element model development, assessment procedure, validation and parametric analysis of the size and location of the low yield zones in the elbow fittings. The fittings are analyzed for three possible operating scenarios: internal pressure, internal pressure with opening moment and internal pressure with closing moment. To characterize the influence of the low yield zone on the strength of the pipe, a parameter termed as “effective yield strength” is introduced. This approach is further demonstrated and found suitable for predicting burst pressures of components with lower yield zones of various diameters and thicknesses. This assessment method can be further extended to assess other pipeline components that exhibit similar behavior.

A Method to Estimate Deformation Strains in the Context of Coke Drum Life Assessments: Part 1

In this paper, an analytical method to estimate the deformation strains that can quantify the severity of bulges, as it applies to coke drums, is presented. The proposed method is based on classical shell theory and API 579-1/ASME FFS-1 (2016) procedures involving triaxiality limits. In this first part of the work, only the theoretical development is presented along with the comparison of the results from this theoretical approach with two case studies that emulate the bulging due to different loading scenarios. The developed approach is then applied to a deformed coke drum. In the next part of this paper, the application of this approach on selected in-service coke drums that are equipped with strain gages will be presented. The authors would like to emphasize the well-known fact that the coke drum is a complex pressure vessel for which any single simplified assessment technique may not be sufficient to quantify the life or fitness-for-service (FFS) of a coke drum due to the complexities associated with the various parameters that affect the mechanical integrity of the coke drum. This paper is an attempt to advance the assessment techniques that are currently utilized in the industry.

Brittle Fracture Assessments on Piping Systems: MSOT Curves

Brittle fracture assessments (BFAs) of pressure vessels based on API 579-1/ASME FFS-1, Section 3 procedures are frequently easier and more straightforward to implement in comparison to the BFAs on piping systems. Specifically, the development of the MSOT curves. This is due to the complexities involved in the piping systems due to the branch piping interactions, end conditions of piping systems such as nozzle flexibilities at the pressure vessel connections, temperature changes in the length of piping especially when the piping is significantly long as seen in flare header piping systems. MSOT curves that are alternatively used for MAT curves provide a better picture to the plant personnel in understanding the safe operating envelope. Development of MSOT curves is an iterative process and therefore involves significant number of piping stress analyses during their development. In this paper, an approach to develop the MSOT curves is discussed with two case studies that are of relevance to olefin plants.

Engineering Critical Assessment of Post Weld Heat Treatment for Full-Encirclement Tees Greater Than 1.25 Inches

Full-encirclement split tee fittings for hot tapping and plugging (HT&P) wrap completely around the pipeline and are welded in place. The welded joint provides mechanical reinforcement of the pipe and branch. When full-encirclement hot tap tees are welded to pipelines 24 inches in diameter or larger, the header must often be at least 1.25 inches thick to pass the required calculations for reinforcement. This means the joint will require post weld heat treatment (PWHT) according to ASME B31.8 and CSA Z662. However, PWHT can be extremely dangerous and impractical, potentially elevating temperature to the point where material strength of the pressurized pipeline is compromised. An engineering critical assessment per ASME FFS-1/API 579 indicated PWHT may not be required for a full-encirclement hot tap tee over 1.25 inches thick. Specifically, research showed that the residual stresses developed during the welding process may not limit the design of a full-encirclement tee or lead to shorter pipeline design life. This paper illustrates how a “more rigorous analysis” per paragraph 802.2.2[b] of ASME B31.8 and paragraph 4.3.12.2 of CSA Z662 may help operators avoid the PWHT requirement. It discusses the finite element analysis (FEA) simulations researchers used to induce residual stresses in a carbon steel fitting. The residual stresses induced in the fitting were used as initial condition for plastic collapse and fatigue evaluations.

A Study of the Conservatism in ASME BPVC Section VIII Division 2 Opening Design for External Pressure

In the ASME Boiler and Pressure Vessel Code, nozzle reinforcement rules for nozzles attached to shells under external pressure differ from the rules for internal pressure. ASME BPVC Section I, Section VIII Division 1 and Section VIII Division 2 (Pre-2007 Edition) reinforcement rules for external pressure are less stringent than those for internal pressure. The reinforcement rules for external pressure published since the 2007 Edition of ASME BPVC Section VIII Division 2 are more stringent than those for internal pressure. The previous rule only required reinforcement for external pressure to be one-half of the reinforcement required for internal pressure. In the current BPVC Code the required reinforcement is inversely proportional to the allowable compressive stress for the shell under external pressure. Therefore as the allowable drops, the required reinforcement increases. Understandably, the rules for external pressure differ in these two Divisions, but the amount of required reinforcement can be significantly larger. This paper will examine the possible conservatism in the current Division 2 rules as compared to the other Divisions of the BPVC Code and the EN 13445-3. The paper will review the background of each method and provide finite element analyses of several selected nozzles and geometries.

Prediction of Fracture Location in Tensile Test of Short-Fiber-Self-Reinforced Polyethylene Composite Plates

Composite materials such as carbon-fiber-reinforced plastics (CFRP) and glass-fiber-reinforced plastics (GFRP) have been attracting much attention from the viewpoint of lightweight solution of automobiles and airplanes. However, the recyclability of these composite materials is not sufficient and the environmental load is large. Recently, self-reinforced polymer (SRP), in which similar polymer is used for reinforcing fibers and matrix, has been proposed. High-density polyethylene (HDPE) reinforced with ultra-high-molecular-weight polyethylene (UHMWPE) fibers, so-called self-reinforced PE (SRPE), is one of the promising thermoplastic composites. In this study, SRPE plates were made and the tensile tests were carried out. After the effect of reinforcement of UHMWPE fibers was evaluated on the basis of the tensile strength, the relationship between the distribution of UHMWPE fibers and the location of the final fracture line was examined. It was found from these experimental results that the fracture tends to occur along the regions with low area fraction of fibers or along those with low area fraction of fiber/matrix boundaries. This fact suggests that the fracture location of SRPs is predictable from the distribution of reinforcing fibers.

Study on Buckling Strength Reduction Factor for Vertical Vessel Skirts With Access Opening by Elastic-Plastic Analysis

Access opening is a key geometric feature of vertical vessel skirts. To ensure the structural stability of skirts, buckling strength reduction caused by openings shall be numerically evaluated. In the previous study, Buckling Strength Reduction Factor (BSRF) was introduced as a design factor representing the effects of openings. However BSRF is based on the elastic bifurcation buckling under axial compressive load. The relations between BSRF and practical design conditions, such as bending moment, material plasticity, and local deformation, are not yet evaluated. The purpose of this paper is to develop the buckling design method for vertical vessel skirts with access opening by investigating the relation between BSRF in consideration of practical design conditions and conventional design concepts for straight cylinder. The finite element analyses of buckling strength were conducted for cylindrical shells with and without openings under bending moments. In addition, nonlinear buckling behaviors of skirts with opening were studied by elastic-plastic analyses and limit-load analyses. These studies revealed the relation between BSRF and conventional buckling design concepts. Based on these results, a new buckling design approach which includes the application BSRF was proposed. This proposed approach provides a practical guide for buckling design of vertical vessel skirts with access opening.

Further Work on Analyzing Accuracy and Overall Performance of Torque Tools for Assembling Bolted Flanged Joints

Over the past two years, the accuracy and repeatability of equipment used to assemble bolted flanged joints have been studied, and progress has been reported in past papers. One of the findings has been that pneumatic torque wrenches demonstrated a broader plus/minus range on bolt stress from the targeted value (e.g., lack of accuracy) than manual or hydraulic torque wrenches. What was notable, however, was that the repeatability of the bolt stress that was achieved did remain consistent with the other types of torque wrenches. Since the repeatability has been shown to be consistent, attention has turned to investigating and determining the reason for the perceived lack of accuracy. One aspect that might account for this is the calibration of the pneumatic torque wrenches. This paper outlines and documents the research that has recently taken place to identify the parameters that are key elements in improving the accuracy of pneumatic torque wrenches that might form the basis of development of a standard for calibration of powered torqueing equipment.

Adjusted J-R Toughness Curve for Pipes Using J-A2 Crack Constraint of CT Specimens and 3D Crack Meshes

The objective of this paper is to use two-parameter fracture mechanics to adjust a material J-R resistance curve (i.e. toughness) from the test specimen geometry to the cracked component geometry. As most plant equipment is designed and operated on the “upper shelf”, a ductile tearing analysis may give a more realistic assessment of flaw tolerance. In most cases, tearing curves are derived from specimen geometries that ensure a high degree of constraint, e.g., SENB and CT Therefore, there can be significant benefit in accounting for constraint differences between the specimen geometry and the component geometry. In one-parameter fracture mechanics a single parameter, K or J-integral, is sufficient to characterize the crack front stresses. When geometry dependent effects are observed, two-parameter fracture mechanics can be used to improve the characterization of the crack front stress, using T-stress, Q, or A2 constraint parameter. The A2 parameter was be used in this study. The usual J-R power-law equation has two coefficients to curve-fit the material data (ASTM E1820). The adjusted J-R curve coefficients are modified to be a function of the A2 constraint parameter. The measured J-R values and computed A2 constraint values are related by plotting the J-R test data versus the A2 values. The A2 constraint values are computed by comparing the HRR stress solution to the crack front stress results of the test specimen geometry using elastic-plastic FEA. Solving for the two J-R curve coefficients uses J values at two Δa crack extension values from the test data. A closed-form solution for the adjusted J-R coefficients uses the properties of natural logarithms. The solution shows the adjusted J-R exponent coefficient will be a constant value for a particular material and test specimen geometry, which simplifies the application of the adjusted J-R curve. A different test specimen geometry can be used to validate the adjusted J-R curve. Choosing another test specimen geometry, having a different A2 constraint value, can be used to obtain the adjusted J-R curve and compare it to the measured J-R curves. The geometry of the component is also expected to have a different A2 constraint compared to the material test specimen. The example examined here is an axial surface flaw in a pipe. The A2 constraint for an axial surface cracked pipe is computed and used to obtain an adjusted J-R curve. The adjusted J-R curve shows an increase in toughness for the pipe as compared to the CT measured value. The adjusted J-R curve can be used to assess flaw stability using the driving force method or a ductile tearing instability analysis.

The Evolution of Bulged Areas in the Cylindrical Section of Coke Drums

In recent years the understanding of the relationship between drum damage and bulge sharpness has improved significantly. The authors of this paper developed a new parameter called bulge sharpness and have previously shown the relationship between sharpness and observed damage. Further to this study, the authors have exhaustively studied the evolution of stress cracking (elephant skin) on mid-course bulges and have estimated the likelihood of finding a particular type of surface damage based on the observed sharpness levels. This correlation has led to a proposed scale to categorize stress cracking into three levels: minor, intermediate, and significant. In addition, the progression of bulge sharpness over time was analyzed and it was determined through statistical modeling that bulge sharpness can have a range of rates of change or sharpness growth rates: low, medium, and high. These sharpness growth rates were subsequently studied and their relationship with overall cycle times analyzed. The study also shows that individual coke drums can experience different sharpness growth rates and there can be a distribution of these rates. To determine when repairs should be conducted, coke drum operators must consider the expected operational run. While the random nature of coke drum damage can defy such targets, bulge sharpness growth assessments can be used to better define when repairs should be conducted. Understanding current bulge sharpness levels, year-over-year sharpness growth rates and their distribution, can significantly assist in targeting areas of concern for optimized repair strategies and can also be used to avoid unnecessary repairs.