Fitness-for-service (FFS) assessments are quantitative engineering evaluations performed to assess the structural integrity of an in-service component that may be flawed or damaged. The FFS standard committee of the Petroleum Association of Japan and the Japan Petrochemical Industry Association is developing the Japanese FFS standard based on the API⁄ASME FFS code for metal loss assessment using the finite element method (FEM) . The FEM is described in ANNEX B in API-579-1⁄ASME FFS-1. As stated therein, evaluations of at least plastic collapse (B 1. 2) and local failure (B 1. 3) are required to be performed for the assessment of metal loss.
The FFS standard committee members calculated the acceptable pressure inside a cylindrical shell with local metal loss by the FEM using burst test data obtained from a public database, in order to estimate the safety margin of the burst pressure.
It was found that the accuracy of the acceptable pressure for plastic collapse calculated by the committee members varied within 5% of the safety margin despite the use of the same software and FEM mesh; the safety margin is defined as the ratio of the burst pressure to the calculated acceptable pressure and is approximately equal to Safety Factor in the Code.
Further, the safety margin of the hand-calculated acceptable pressure described in Part 5 of API-579-1⁄ASME FFS-1 is more conservative than that of the FEM results.
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