asme life cycle - importante

ASME Life Cycle Management of Pressure Equipment Integrity

David Lang FM Global

Forest Products Operations – Dallas, TX In 1993, ASME initiated activity to address the development of post construction standards in response to an identified need for recognized and generally accepted engineering standards for the inspection and maintenance of pressure equipment after it has been placed in service. In 1995, the Post Construction Committee (PCC) was appointed to develop and maintain standards addressing common issues and technologies related to post-construction activities, and to work with other consensus committees in the development of separate, product-specific codes and standards. As a result, ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly was published in 2000, ASME PCC-2 Repair of Pressure Equipment and Piping was published in 2006, ASME PCC-3 Inspection Planning Using Risk-Based Methods was published in 2007 and API 579/ASME FFS-1 Fitness-For-Service was published in 2007. In the course of preparing the documents described above, the Post Construction Committee recognized the need to provide a guideline or “roadmap” to help users navigate the volumes of codes, standards, recommended practices, specifications and guidelines related to the overall concept of life cycle management of pressure equipment. As a result, PTB-2 Guide to Life Cycle Management of Pressure Equipment Integrity was published in 2009. Life-Cycle Management (LCAM) – The Whole Story(1)

Formal process that governs all business activities that directly or indirectly affect the reliability, maintainability, and life cycle of the capital assets that comprise the plant or facility

– Standard Processes (SOP) that govern how each phase of an Asset’s Life Cycle from conception to disposal – Standard Work Procedures (SWP) that govern each step within a phase of the asset’s life cycle, functional

specification, development, installation, etc.

Life-Cycle Management – Portioned for the 2010 TAPPI Peers Conference

The overall concept of life cycle management is far reaching. For the purposes of this discussion, we will touch on only a couple of key points. The concepts of life cycle management are likely not appropriate for all pressure containing equipment. Most often, routine components such as industrial boilers, tanks and piping are suitably managed with simple time-based prescriptive inspection programs. The concepts of life cycle management as presented here are generally better suited to large or complex power boilers and specialty tanks and process equipment. These may include specialty boilers such as black liquor recovery boilers, hog-fuel boilers, digesters, steaming vessels and even where there are large numbers of similar objects such as dryer rolls. The simplistic fundamental thought is that candidate pressure equipment is built to a recognized code or standard with consideration for baseline information and provisions for foreseeable inspection and maintenance. The equipment is installed, started, operated and maintained in accordance with a pre-established plan and recognized practice. An inspection is planned and executed. If the results warrant no additional action, the results are fed back to the inspection plan and the inspection plan amended as appropriate. If the inspection shows potential indications of problems, the pressure equipment is evaluated in accordance with recognized fitness-for-service processes. If no repair is required, that information is fed back to the inspection plan and the inspection plan amended as appropriate. If repairs are required, appropriate repairs are completed and again, the results are fed back to the inspection plan and the inspection plan amended as appropriate. Naturally, at any stage of this process, equipment replacement or retirement is a possible alternative.

PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly

A Bolted Flange Joint Assembly (BFJA) is a complex mechanical device; therefore, BFJAs that provide leak-free service are the result of many selections/activities having been made/performed within a relatively narrow band of acceptable limits. One of the activities essential to leak-free performance is the joint assembly process. The guidelines outlined in this document cover the assembly elements essential for a high level of leak-tightness integrity of otherwise properly designed/constructed BFJAs. It is recommended that written procedures, incorporating the features of these guidelines that are deemed suitable to the specific application under consideration, be developed for use by the joint assemblers. Alternative features and methods for specific applications may be used subject to endorsement by the user or his designated agent. The bolted flange joint assembly (BFJA) guidelines described in this document apply to pressure-boundary flanged joints with ring-type gaskets that are entirely within the circle enclosed by the bolt holes and with no contact outside this circle. By selection of those features suitable to the specific service or need, these guidelines may be used to develop effective joint assembly procedures for the broad range of sizes and service conditions normally encountered in industry. Guidance on troubleshooting BFJAs not providing leak-tight performance is also provided in this document PCC-2 Repair of Pressure Equipment and Piping

This Standard provides methods for repair of equipment and piping within the scope of the ASME Pressure Technology Codes and Standards after it has been placed in service. These repair methods include relevant design, fabrication, examination, and testing practices and may be temporary or permanent, depending on the circumstances. The methods provided in this standard address the repair of components when repair is deemed necessary based on appropriate inspection and flaw assessment. These inspection and flaw evaluation methods are not covered in this document, but are covered in other post-construction codes and standards. Only technical procedures and information are provided; administrative or policy requirements are outside of the scope of this Standard. PCC-3 Inspection Planning Using Risk-Based Methods

This Standard provides information on using risk analysis to develop and plan an effective inspection strategy. Inspection planning is a systematic process that begins with identification of facilities or equipment and culminates in an inspection plan. Both probability of failure and the consequence of failure should be evaluated by considering all credible damage mechanisms that could be expected to affect the facilities or equipment. In addition, failure scenarios based on each credible damage mechanism should be developed and considered. The output of the inspection planning process conducted according to these guidelines should be an inspection plan for each equipment item analyzed that includes: a) Inspection methods that should be used. b) Extent of inspection (percent of total area to be examined or specific locations) c) Inspection interval (timing) d) Other risk mitigation activities. e) The residual level of risk after inspection and other mitigation actions have been implemented. The risk analysis principles, guidance, and implementation strategies presented in this Standard has been specifically developed for applications involving fixed pressure-containing equipment and components. This Standard is not intended to be used for nuclear power plant components; see ASME BPV, Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components. It provides guidance to owners, operators, and designers of pressure-containing equipment for developing and implementing an inspection program. These guidelines include means for assessing an inspection program and its plan. The approach emphasizes safe and reliable operation through cost-effective inspection. A spectrum of complementary risk analysis approaches (qualitative through fully-quantitative) should be considered as part of the inspection planning process.

API 579-1/ASME FFS-1 Fitness for Service

The ASME and API new construction codes and standards for pressurized equipment provide rules for the design, fabrication, inspection and testing of new pressure vessels, piping systems, and storage tanks. These codes do not provide rules to evaluate equipment that degrades while in-service and deficiencies due to degradation or from original fabrication that may be found during subsequent inspections. API 510, API 570, API 653, and NB-23 Codes/Standards for the inspection, repair, alteration, and rerating of in-service pressure vessels, piping systems, and storage tanks do address the fact that equipment degrades while in service. Fitness-For-Service (FFS) assessments are quantitative engineering evaluations that are performed to demonstrate the structural integrity of an in-service component that may contain a flaw or damage. This Standard provides guidance for conducting FFS assessments using methodologies specifically prepared for pressurized equipment. The guidelines provided in this Standard can be used to make run-repair-replace decisions to help determine if pressurized equipment containing flaws that have been identified by inspection can continue to operate safely for some period of time. These FFS assessments are currently recognized and referenced by the API Codes and Standards (510, 570, & 653), and by NB-23 as suitable means for evaluating the structural integrity of pressure vessels, piping systems and storage tanks where inspection has revealed degradation and flaws in the equipment. The methods and procedures in this Standard are intended to supplement and augment the requirements in API 510, API 570, API 653, and other post construction codes that reference FFS evaluations such as NB-23. The assessment procedures in this Standard can be used for Fitness-For-Service assessments and/or rerating of equipment designed and constructed to the following codes: a) ASME B&PV Code, Section VIII, Division 1 b) ASME B&PV Code, Section VIII, Division 2 c) ASME B&PV Code, Section I d) ASME 831.1 Piping Code e) ASME 831.3 Piping Code t) API 650 g) API620 The assessment procedures in this Standard may also be applied to pressure containing equipment constructed to other recognized codes and standards, including international and internal corporate standards. This Standard has broad application since the assessment procedures are based on allowable stress methods and plastic collapse loads for non-crack-like flaws, and the Failure Assessment Diagram (FAD) Approach for crack-like flaws.

ASME PTB-2 Guide to Life Cycle Management of Pressure Equipment Integrity

As noted above, in the course of preparing the documents described above, the Post Construction Committee recognized the need to provide a guideline or "roadmap" to help users of pressure equipment and their designated agents, as well as manufacturers, owners, regulators and other stakeholders, identify the codes, standards, recommended practices, specifications and guidelines that apply to the life cycle management of pressure equipment integrity. Accordingly, ASME held a workshop in March 2009 to review a proposal for guidance that provides an integrated approach to the understanding and application of technologies in these standards in engineering programs for management of the life cycle of pressure equipment, including inspection, fitness for continued service and repair. The transition from new construction to post construction was an essential part of this study, as new construction standards address inspectability and provide a baseline critical to any post-construction assessment. The post construction standards presented and reviewed included: PCC-1 -2000 Guidelines for Pressure Boundary Bolted Flange Joint Assembly PCC-2-2006 Repair of Pressure Equipment and Piping Standard PCC-3-2007 Inspection Planning Using Risk-Based Methods API 579-lIASME FFS-l 2007 Fitness-For-Service This Guide is intended to fill that need. It is not intended to be an industry standard, but rather to provide general guidance. Also note that this document is not intended to be a complete listing of all of the publications related to pressure equipment integrity, which would fill many bookshelves, but rather lists the most pertinent references in the opinion of the author and the reviewers. This guide provides a summary of some of the more commonly used codes, standards, recommended practices (RPs), specifications and guidelines produced by organizations based in the United States that assist manufacturers, owners, users and their designated agents, regulators and other stakeholders in maintaining the integrity of fixed pressure equipment in process plants and in general industrial use. For the convenience of the user of this guide, the term "documents" will be used throughout to refer collectively to "codes, standards, recommended practices, specifications and guidelines." This guide is not all-inclusive. There are many documents that are useful for specific applications of pressure equipment that have not been described or included as references in this guide. This does not imply that these documents should not be used or

that they have any deficiencies. Note also that engineering knowledge and experience is necessary for the proper application of most of the standards listed. The following applications for pressure equipment are not specifically included in the scope. However, the owner of these categories of equipment may use those portions of this guide that are applicable: a) Upstream "non-process" equipment in the oil and gas industry (e.g., pressure equipment used in oil and gas

exploration and production such as Christmas trees, wellhead equipment, flow lines, subsea equipment) b) Equipment in commercial nuclear power plants c) Domestic plumbing and other domestic pressure equipment such as hot water heaters. Portable air receivers

(air tanks) used by homeowners and contractors are excluded from the scope but air receivers in industrial facilities are included

d) Liquefied natural gas (LNG) and liquefied petroleum gas (LPG) transport and storage (API and ship classification societies)

e) Pipelines f) Pressure equipment used in transport service. This guide includes only documents that are pertinent to maintaining equipment integrity (e.g. pressure containment) through appropriate design, construction, inspection, maintenance, alteration and repair. Standards related to areas such as identification schemes, plant or pipeline operator qualification, etc. are outside of its scope. The inclusion of a document in this guide does not imply that the document is endorsed by ASME. This listing is provided only for the convenience of manufacturers, users and their designated agents, regulators and other stakeholders to help identify documents that are potentially applicable. Conclusions Life-cycle management of pressure part integrity is a multi-faceted program with some aspects regulated by law, others stimulated by the need for reliability, operability and maintainability. Except for the regulated aspects, the remainder is generally voluntary and there are a tremendous number of resources available on the subject – They are just a little hard to select and piece together to get what you want. Some of the available guidance is redundant in scope and application. Passing along only a life-time of experience with Codes, Standards, Regulations, Guidelines and References is not enough anymore. New materials are continuously being made available. PTB-2 which is attempting to sort out all of the currently available information is a very early stage step in the right direction. It needs input from TAPPI, BLRBAC and all of the other documents driving our work processes. References

(1) Copyright, Life Cycle Engineering, www.LCE.com

Dave LangFM Global

ASME LIFE-CYCLE MANAGEMENT OF PRESSURE

EQUIPMENT INTEGRITY

DISCLAIMER

WHO AM I ?

Formal process that governs all business activities that

directly or indirectly affect the reliability, maintainability, and life cycle of the capital

assets that comprise the plant or facility

(Life Cycle Engineering)

CONCEPTIONDESIGNPROCURECONSTRUCT

COMMISSIONOPERATEMAINTAINDECOMMISSION

New Construction

Inspection Planning Findings?Successful?

Fitness for ServiceRepair & Testing Repairor Replace?

Inspect

No

Yes

Yes

Assess

No

No

Yes

Operation & Maintenance

Installation

Inspection Planning Findings?Successful?

Fitness for ServiceRepair & Testing Repairor Replace?

Inspect

No

Yes

Yes

Assess

No

No

Yes

Operation & Maintenance

NO BOLTS

Other Codes & Standards

ASME SECTION I

POWER BOILERS

ASME SECTION I POWER BOILERSASME SECTION

IX WELDING

ASME SECTION I –POWER BOILERS

ASME SECTION IX –WELDING

ASME SECTION II -MATERIALS

ASME SECTION I – POWER BOILERS

ASME SECTION IX –WELDING

ASME SECTION II -MATERIALS

ASME SECTION V – NDE

ASME SECTION I – POWER BOILERS

ASME SECTION IX – WELDINGASME SECTION II - MATERIALS

ASME SECTION V – NDEASME SECTION VIII – PRESSURE

VESSELS

ASME SECTION I – POWER BOILERSASME SECTION IX – WELDING

ASME SECTION II - MATERIALSASME SECTION V – NDE

ASME SECTION VIII – PRESSURE VESSELS

ANSI/ASME B31.1 – POWER PIPING




ANSI/ASME B31.1 – POWER PIPINGASME SECTION I– BOILER PROPER

PIPING




ANSI/ASME B31.1 – POWER PIPINGASME SECTION I– BOILER PROPER

PIPINGNBIC – RULES FOR INSTALLATION



ASME SECTION VIII – PRESSURE VESSELSANSI/ASME B31.1 – POWER PIPING

ASME SECTION I– BOILER PROPER PIPINGNBIC – RULES FOR INSTALLATION

BLRBAC – OTHER GUIDANCE FOR SETTING UP





BLRBAC – OTHER RULES FOR SETTING UPBLRBAC – GUIDANCE FOR OPERATION





BLRBAC – OTHER RULES FOR SETTING UPBLRBAC – RULES FOR OPERATION

NBIC – RULES FOR INSPECTION






NBIC – RULES FOR INSPECTIONTAPPI TIPS – INSPECTION




ASME SECTION I – BOILER PROPER PIPINGNBIC – RULES FOR INSTALLATION


NBIC – RULES FOR INSPECTIONTAPPI TIPS – INSPECTIONNBIC – RULES FOR REPAIR







AWS SWPS CAN BE USED FOR WELDING MY REPAIRS







NBIC ALLOWS AWS SWPS FOR WELDED REPAIRSASME – REPAIR AND TESTING








ASME/API – FITNESS FOR SERVICE








ASME/API – FITNESS FOR SERVICEBLRBAC WELDING AND MATERIALS








ASME/API – FITNESS FOR SERVICEBLRBAC – WELDING AND MATERIALS

NATIONAL BOARD “R” STAMP








ASME/API – FITNESS FOR SERVICEBLRBAC – WELDING AND MATERIALS

NATIONAL BOARD “R” STAMPAUTHORIZED INSPECTION AGENCY - FOR REPAIRS








ASME/API – FITNESS FOR SERVICEBLRBAC – MATERIALS & WELDING


JURISDICTIONS FOR OPERATING CERTIFICATES








ASME/API – FITNESS FOR SERVICEBLRBAC – MATERIALS & WELDING


JURISDICTIONS FOR OPERATING CERTIFICATESINSURANCE COMPLANIES – BECAUSE THEY ARE FUN

Types of documents covered:CodesStandardsRecommended PracticesSpecificationsGuidelinesTechnical PublicationsOther Useful References

Types of documents not covered:Laws / regulations

BLRBAC (0)API (53)ASME (54)MTI (18)WRC (17)

NACE (5)EPRI (3)ASNT (2)NB (2) TEMA (1)ASCE (1)

TAPPI (0)

NONE

ZIP

ZILCHNADA

AIN’T

ANYAUCUN

Нито една

代詞

אף אחד

Ingen

ไม่มีŽádný

Nuttin’

NOGOTS

Geen

Organized by type of pressure equipment to which the various standards are applicable:

Boilers (power / heat recovery / heating / unfired)Pressure Vessels (typical / high pressure / HX)Storage Tanks (atmospheric / low pressure)Piping Systems and ComponentsOverpressure ProtectionGeneral (Welding / NDE)

Each PEI standard for each type of pressure equipment is categorized as being applicable to these six phases of LCM:

Specification / PurchaseDesign / Fabrication / ConstructionOperationIn-Service Inspection Fitness-for-Service AnalysisRepair

BLRBAC?

TAPP

I?

Example: Documents listed as applicable to each of the 6 categories for pressure vessels:

Specification / Purchase – 12 docsDesign / Fabrication / Construction –14 docsOperation – 0 docsIn-Service Inspection – 11 docs Fitness-for-Service Analysis – 2 docsRepair – 8 docs

Example: Documents listed as applicable to each of the 6 categories for steam boilers:

Specification / Purchase – 5 docsDesign / Fabrication / Construction –10 docsOperation – 1 docIn-Service Inspection – 10 docs Fitness-for-Service Analysis – 2 docsRepair – 7 docs

BUT, YOU SAY………

Mr. Lang – Mr. Lang,

My stuff was built to ASME but yet you reference API and other documents.

Can I use those on my ASME stuff?

Well, I’m here to say………….

Yes you may.

Provided you have met or will meet the intent of Jurisdictional and other MANDATORY requirements

Each of about 140+ standards has a concise “Readers Digest”of its contents, including:

TitleCurrent edition and publication dateNumber of pagesANSI approved?ScopeApplication of the standardHighlights of the contentsTypical users of the document

Examples of Summary of Referenced

Standards

RP-SNT-TC-1AASNT Q&C Of Personnel

CP-189ASNT Q&C Of Personnel

ASME SECTION IPower Boilers

ASMESECTION IXWelding

RP-571Damage Mechanisms

RP-578MaterialVerificationProgram