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Becht Engineering
www.Becht.com
Fall 2010
Newsletter
Autorefrigeration
and Brittle Fracture
Continued on Page 4
A
team of Becht engineers, in collaboration with
owner/operator personnel, recently completed a
successful Risk-Based Inspection (RBI) Assess-
ment and a Turnaround Risk Based Work Selec-
tion (TA/RBWS) Assessment for a major complex refnery
in the Gulf Coast. Tese assessments enabled the refnery to
closely evaluate a very ambitious work scope for an upcoming
turnaround and resulted in a signifcant savings to the work
scope of approximately $10 to $15 million.
API inspection codes and standards allow owner/operators
the ability to plan an inspection strategy (increase or decrease
the inspection frequencies) and/or replace turnaround inspec-
tions with alternative on-line risk mitigation approaches based
on the results of a risk-based inspection assessment. Tese as-
sessments must systematically evaluate both the probability of
failure and the associated consequence of failure. Te probabil-
ity of failure assessment must consider all forms of deteriora-
tion that could reasonably be expected to afect the piece of
equipment in the particular service.
Te intent of this project was to assist the refnery in fnal-
izing their work scope for an upcoming Turnaround. Te as-
sessments included Fixed Equipment, Fired Heaters, Rotating
Equipment, Electrical Systems, Motors, Instrumentation, Pip-
ing and Valves, and Flare systems which covered a number of
Process Units throughout the refnery.
Te RBI and TA/RBWS assessments included the applica-
tion of the clients corporate risk matrix for determination of
risk levels and risk reduction. Te RBI assessments for Fixed
Equipment utilized Bechts proprietary software tool STI-
ER (Strategic Tool for Improving Equipment Reliability).
Te TA/RBWS assessments covered Work List items includ-
ed in the refnerys Turnaround Plans. Te RBWS incorpo-
rated Bechts Risk Based Beneft Cost Analysis (RBBCA) for
equipment items that have a high fnancial impact. Equipment
in each Process Unit was assessed by the refnery teams for
inclusion in the TA Work List or for elimination, or deferment
to a future turnaround.
Te work was completed by a team of Senior Specialists
from Becht Engineering Company that included Arcot Rad-
hakrishnan, Eileen Chant, Phong Diep, Don Bagnoli and
Jerry Horak. Over 50 refnery personnel including Operations
Risk-Based Inspection
& Risk Based Work
Selection A Key to
Signicant Savings
on Turnarounds
BY ARCOT RADHAKRISHNAN & EILEEN CHANT, PhD, PE
A
utorefrigeration and the potential for brittle frac-
ture of pressure containing equipment represent
signifcant hazards in the petrochemical and refn-
ing industry. One company Becht Engineering has
worked with on remediation of this hazard has experienced via
legacy organizations at least four major incidents resulting in
sudden, catastrophic failure of pressure containing equipment.
One incident resulted in two fatalities. Tis demonstrates that
the hazard is quite real and in fact over 100 brittle fractures of
equipment have been documented in the history of the industry.
Since this is a break before leak phenomenon vs. a fairly com-
mon leak before break scenario, brittle fracture is a very serious
hazard since it results in complete, sudden loss of containment.
Te phenomenon of autorefrigeration occurs when light hy-
drocarbon liquid pressures are quickly reduced. Tis can occur
during inventory of equipment when light hydrocarbons are
introduced into vessels at low pressure. It can also occur dur-
ing decommissioning or process upset when materials are de-
pressured into sections of the plant not designed for the low
temperature. Another hazard that can drive brittle fracture is
when light hydrocarbons or other materials at low temperature
migrate to sections of the plant not designed for the low tem-
perature. C3 hydrocarbons, for example, can autorefrigerate to
temperatures below minus 40 degrees F. Many standard ves-
sel materials such as ASTM A-516 Grade 70 are not suitable
for this temperature and can transition from a ductile to brittle
state well above this temperature, depending on the specifc steel
composition, heat treatment history and other factors.
Brittle fracture is possible if the vessel temperature is below
the brittle ductile transition temperature. Brittle fracture is
driven by a model similar to the fre triangle. In the case of
brittle fracture, it is driven by material properties, faw size and
stress. In general, stress levels above 7000 psi are needed to drive
the fracture. As in the fre triangle model, removing one leg of
the triangle eliminates the potential at a given set of tempera-
ture and other conditions. Terefore, designing the vessel for
BY RICK HOFFMAN AND ROBERT SIMS
Continued on Page 4
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INTRODUCTION
O
ne of the activities essential to leak-free perfor-
mance is the joint assembly process. Te guidelines
in PCC-1-2010 entitled Guidelines for Pressure
Boundary Bolted Flange Joint Assembly cover the
assembly elements essential for a high level of leak-tightness in-
tegrity of an otherwise properly designed and constructed bolted
fange joint (BFJ). Te guidelines in the updated PCC-1-2010
document have been greatly expanded over those in PCC-1-
2000, the original document, to cover advances in gasket tech-
nology, bolting assembly procedures and calculation methods, as
well as recommendations based on industry experience with joint
failures. Tis increased coverage resulted in the original 33 page
document being expanded to 77 pages. In reference to keeping
this article relatively brief, only highlights of the major changes/
additions will be made, with the hope and recommendation that
those seriously interested in the full coverage will acquire a copy
for handy reference and follow the guidelines provided therein.
TRAINING, QUALIFICATION AND CERTIFICATION
OF JOINT ASSEMBLY PERSONNEL
Te new proposed Appendix A of this title that will include
certifcation of bolted joint assemblers is under consideration by
the ASME Pressure Technology Post Construction Committee
and endorsement at the Board level is going quite well. It will be
a while, however, before fnal approval and implementation of
the program for the certifcation of bolted joint assemblers will
be available.
CLEANING AND EXAMINATION OF FLANGE AND
FASTENER SURFACES
Tis important topic has been greatly expanded in an
efort to sensitize all users of the importance of the proper
condition of contact surfaces in achieving the sealing (gasket
contact surfaces) and translation of torque to load in the bolt
(thread and nut content surfaces). See also new Appendices D
(Guidelines for Allowable Gasket Contact Surface Flatness
and Defect Depth); and N (Defnitions, Commentary, and
Guidelines on the Reuse of Bolts) for this information.
ALIGNMENT OF BOLTED JOINTS
Proper alignment of all joint members is an essential element
of fange joint assembly. See new Appendix E (two pages) for
details. Tese new and efective guidelines refect the critical
interrelationship between the initial alignment and the force
required to bring the joint into alignment (system stifness).
I
n addition to the many clarifcations, updates to referenced
codes and standards, and updates to basic allowable stresses,
there are several substantive changes to the 2010 Edition of
ASME B31.3, Process Piping. Tese changes are:
HIGH PURITY FLUID SERVICE
Requirements for fuid services designated as High Purity
are added. High Purity Fluid Service is defned as a fuid
service that requires alternative methods of fabrication,
inspection, examination, and testing not covered elsewhere
in the Code with the intent to produce a controlled level of
cleaness. Requirements include:
Additional requirements for compression fttings.
Recommendations for the use of heavy duty two-bolt
clamp in lieu of hinged tri-clamp for systems subject to
temperature and pressure fuctuations.
Weld coupon examination is an acceptable substitute to
the 5% random radiography or ultrasonic examination
required for Normal Fluid Service.
Allows a helium mass spectrometer test to be used for a
pneumatic leak test.
STRESSES DUE TO SUSTAINED LOADS
A better explanation of what is required to meet the
sustained load stress criteria and the detailed calculation
method formerly described in Case 178 are incorporated.
Sustained conditions may be evaluated by detailed analysis,
approximate methods, or simplifed means such as span tables.
When detailed analysis is performed, the stress due to sus-
tained loads, SL shall be computed and combined as described
in [para. 320].
Te para. 320 detailed calculation method includes the for-
mula:
S
L
= [(|S
a
|+S
b
)
2
+(2S
t
)
2
]
1/2
Where
S
a
= direct axial stress
S
b
= bending stress = [(I
i
M
i
)
2
+ (I
o
M
o
)
2
]
1/2
/ Z
S
t
= torsional stress = M
t
/ (2Z)
I
i
= greater of 0.75i
i
and 1.00
I
o
= greater of 0.75i
o
and 1.00
FILLER METAL
Additional requirements for weld fller metal are added.
Added requirements include:
Te nominal tensile strength of the weld metal shall
equal or exceed the minimum specifed tensile strength
of the base metals being joined
Major Changes/Additions
Included in ASME PCC-
1-2010, Guidelines For
Pressure Boundary Bolted
Flange Joint Assembly
ASME B31.3
Major Changes in
the 2010 Edition
BY CLYDE NEELY, PE
BY DON FRIKKEN, PE
Continued on Page 5 Continued on Page 3
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Te nominal chemical analy-
sis of the weld metal shall
be similar to the nominal
chemical analysis of the major
alloying elements of the base
metal
When austenitic steels are
joined to ferritic steels, the
weld metal shall have a
predominantly austenitic
microstructure.
For nonferrous metals, the
weld metal shall be that rec-
ommended by the manufac-
turer
SOCKET WELD SIZE
Te minimum size for a socket
weld is changed from 1 times the
pressure design thickness to 1.09
times the nominal wall thickness.
TESTING LINES OPEN TO
THE ATMOSPHERE
Lines open to the atmosphere are
exempted from leak testing.
PNEUMATIC LEAK TEST
PRESSURE
Te pneumatic leak test pressure
is changed from 110% of design to
a range of from 1.1 to 1.33 times
design.
HIGH PRESSURE FLUID
SERVICE
Requirements are changed to
permit hammer unions having
Acme straight threads and certain
fareless tubing fttings to be
used. Examination requirements
are changed to permit the use
of ultrasonic examination as an
alternate to radiography under
certain conditions.
METRIC STRESS VALUES
Basic allowable stresses in MPa
frst appear. For this edition, the psi
values are the standard.
ASME B31.3
(Continued from Page 2)
ASME Committees
Board of Governors member and former member
Board on New Development member and current Chair
Council on Standards member and two former Chairs
Board on Hearings and Appeals past Chair
Board on Nuclear Codes and Standards member
Board on Pressure Technology Codes and Standards ve past members
Board on International Standards past member
Boiler and Pressure Vessel Code Committees
Technical Oversight Committee (former Main Committee) - member
Committee on Pressure Vessels (BVC VIII) member and current Chair
Subgroup on High Pressure Vessels (Section VIII, Div 3) member and former Chair
Subgroup on Design (BPV VIII) member and past Chair
Subgroup on General Requirements (BPV VIII) member and past Chair
Subgroup on Heat Transfer Equipment (BPV VIII) member and past Chair
Subgroup on Toughness (BPV II & VIII) member
Task Group on Impulsively Loaded Vessels (SC VIII) - member
Special Interpretations Committee (SC-VIII) -member
Committee on Transport Tanks former member
Design and Analysis Committee current Chair
Subgroup on Elevated Temperature Design member and former Chair
Subgroup on Design/Analysis (BPV III & VIII) member and current Chair
Project Team on Hydrogen Tanks - member
Subcommittee on Accreditation - member
Working Group on Piping (SG-D) (BPV III) member
Subgroup on General Requirements (BPV III) - member
Special Working Group on High Density Polyethylene Piping (SC III) member
Standards Committee on Qualication of Mechanical Equipment - member
Piping and Component Codes and Standards
B31, Code for Pressure Piping, Standards Committee two members and former Chair
B31, Code for Pressure Piping, Executive Committee two members
B31.3, Process Piping Section Committee two members and current Chair and former Chair
B31.3 SG on High Pressure Piping past Chair
B31.3 SG on Design member
B31 Code for Pressure Piping, Mechanical Design Committee three members and former Vice-Chair
B31.12 Hydrogen Piping and Pipelines Section Committee - member
B16 Standardization of Valves, Flanges, Fittings, and Gaskets Standards Committee member

Post Construction Standards
Post Construction Standards Committee three members, current Vice Chair, former Chairs
Post Construction Executive Committee three members
SC on Repair and Testing member and current/founding Chair
SC on Inspection Planning two members
SC on Flange Joint Assembly current Chair
SC on Flaw Evaluation former member

ASME/API
ASME/API Joint Fitness-For-Service Committee (API 579/ASME FFS-1) member and Current Vice Chair
API
Committee on Rening Equipment - past member
Task Group on API 580 past member
Subcommittee on Materials and Corrosion past member
Task Group on Materials for Heavy Wall Vessels past Chair
Subcommittee on Heat Transfer Equipment past Chair
Task Group on Shell & Tube Heat Exchangers past member
Task Group on Air Cooled Heat Exchangers past member
Subcommittee on Above Ground Storage Tanks past member
Subcommittee on Piping past Vice Chair
API 582 Welding Guidelines for the Chemical, Oil and Gas Industries past Chair
Other
AWS A5 (Filler Metals) Committee Member- Source for ASME IIC - member
ASTM Committee F-17, Plastic Piping Systems Main Committee - member
ASTM Standards and Certication Board of Directors Member - former Chairman
ASTM Committees C03, C-16, and D-20.23 member
ISA - The International Society for Measurement and Control, SP 93, Sealing Technologies Committee Member
Materials Technology Institutes Technical Advisory Council Committee - member
Materials Technology Institute, Evaluation of Gaskets Committee - member
US TAG for ISO/TC 153/SC 1 Valve Design, Manufacturing, Marking and Testing - member
US TAG for ISO/TC 5/SC 10 - Metallic Flanges and Their Joints - member
US TAG for ISO/TC 197 Hydrogen Technologies - member
Joint ASME IEEE Seismic Qualication Committee former member
ASME-ASCE Joint Task Group on Buried Pipe founding Chair
Process/Industry Practices (PIP): Coatings and Insulation, former Function Team Leader
Society for Protective Coatings (SSPC): Standards Review Committee, former Co-Leader of Maint Painting Comm

CODES AND STANDARDS PARTICIPATION
Becht Engineering staff includes quite a few members of ASME, API, ASTM and AWS
Code Committees, knowledgeable in the correct application of the Code. This includes:
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Risk Based Inspections (Continued from Page 1)
Autorefrigeration (Continued from Page 1)
Supervisors, Process Engineers, Complex Managers, Subject Mat-
ter Experts (SMEs), TA Planners, Reliability Engineers, Inspectors,
and Technicians participated in these assessments. Excellent par-
ticipation by the teams throughout the phases of equipment data
collection, initial screening and analysis, and front end planning as
well as during the RBI and RBWS work processes contributed to
the successful outcome of this work.
In addition to providing a signifcant cost savings to the site, the
RBI Work Process for Fixed Equipment allowed for the develop-
ment of Equipment Reliability Plans (ERPs) for each of the 187
vessels covered by the assessment. Te ERPs describe all pertinent
inspection, maintenance, monitoring and surveillance tasks and ad-
equately defne the scope of work to sustain long term reliability.
Te Equipment Task Lists include work that has been justifed for
TAs and provide the basis for TA Work Lists on future Unit Turn-
arounds.
Te recommended Industry Best Practice for maintaining the
ERPs is to set up a work process which ensures that Inspection
and Operations periodically review data on thickness, and corro-
sion rates, and determine whether the documented risk levels in the
ERPs may need changes. Te development of the Equipment Reli-
ability Plans will now allow the Unit Teams, with oversight from
the Reliability Group, to maintain and update the ERPs to refect
inspection data and operating history. Tis Best Practice will enable
the site to plan ahead for future events, and contribute towards reli-
ability excellence in the long term.
the zero pressure boiling point of the liquid, keeping stress below
threshold values and / or eliminating and minimizing faws will re-
duce the potential for fracture.
It is also important to note that many older vintage pressure ves-
sels constructed of ASTM A-285 Grade C can have transition
temperatures as high as 80 degrees F. Terefore it is critical that hy-
drotest water temperatures be well above the transition temperature.
In addition, extreme care is needed during cold weather start up to
assure the vessel is warmed to temperatures well above the transi-
tion temperature prior to increasing pressure. One of the failures
mentioned earlier was a catastrophic failure of a heavy wall reactor
on hydrotest.
Remediation of older plants should focus on administrative con-
trols, procedures and interlock systems to prevent these situations
rather than high cost material upgrades and equipment replacement.
Becht Engineering can support all aspects of autorefrigeration
and brittle fracture analysis. Tis includes evaluation of minimum
design metal temperatures, process upset scenarios, fracture analysis
and interlock system design.
Becht Engineering developed a tool to facilitate the rapid assess-
ment of brittle fracture risk of existing pressure vessels, using API
579-1 /ASME FFS-1 criteria. Becht has evaluated over 2000 pres-
sure vessels with this tool. An example output is shown in Figure 1
It provides the fuid temperature as a vessel depressurizes, resulting
in autorefrigeration and compares it to the minimum permissible
temperature, given the details of the pressure vessel and the internal
pressure.
Figure 1
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ASME PCC-1-2010 (Continued from Page 2)
INSTALLATION OF GASKET
Reuse of a gasket is generally not recommended, one current
exemption being the kammprofle-type gasket that sometimes
can be reconditioned to original product specifcations.
LUBRICATION OF WORKING SURFACES
When reusing coated bolts or if lubricant is applied to new or
reused coated bolts, the Nut Factor will change and, therefore,
the torque values should be adjusted accordingly (refer to
Appendix K, Nut Factor Calculation of Target Torque).
INSTALLATIONOF BOLTS AND
BOLT LENGTH CONSIDERATION
When the efective stretching length (Lef) is short, the
total initial bolt elongation resulting from the determined
Target Bolt Stress will be a proportionately small value, thereby
resulting in a signifcant percentage reduction in the post-
assembly bolt stress due to normal gasket creep, embedment
losses, and joint heat-up. Te sensitivity to this occurrence
should be given careful attention along with other joint
considerations when selecting the level of Target Bolt Stress. (a
bolt having an efective length shorter than 5 times its nominal
diameter is generally considered to be short.
JOINT ASSEMBLY PATTERNS
Signifcant improvements have been made in joint assembly
patterns and torque increment combinations in new Appendix
F (pages 30-43 covering use of both single and multiple tool
patterns) by requiring less assembly efort than is necessary for
the Table 4 and Table 4.1 modifed legacy methods. Both single
tool and multiple tool patterns are provided.
Te Table 4.1 modifed legacy cross-pattern tightening
sequence and bolt numbering system when using a single tool is
based on the bolt numbering sequence being marked clockwise
on the fange, thereby improving efciency by not requiring
the assembler to have a table for initial and future assembly
reference as is required by the Table 4 Legacy numbering
system.
TIGHTENING METHOD/LOAD-CONTROL
TECHNIQUE
Very informative new information has been included in
Table 3, Recommended Tool, Tightening Method, and Load-
Control Technique Selection Based on Source Conditions.
JOINT PRESSURE AND TIGHTNESS TESTING
Te user is cautioned to consider that the practice of using
temporary gaskets for pressure or tightness testing of systems
that include bolted fange joint assemblies has resulted in
numerous incidents of injury and near injury to assembly
personnel due to blow out failure of these alternative gasket
materials/types. Te use of substitute gaskets during testing
instead of those designed as the fnal seal for the joint is not
recommended.
RECORDS
Te recommended listing of joint assembly record items has been
expanded. One such addition is to include the names of the
joint assemblers Documentation of unanticipated problems and
their solutions, along with recommendations for future assembly
practices for that joint, provides very useful future information.
REFERENCES
A new Section covering a listing of all publications in the updated
Guideline has been added.
NEW APPENDICES
As mentioned previously, the following are new Appendices
Appendix D, Guidelines for Allowable Gasket Contact Surface
Flatness and Defect Depth
Appendix E, Flange Joint Alignment Guidelines
Appendix F, Alternatives to Legacy Tightening Sequence/Pattern
Appendix N, Defnitions, Commentary, and Guidelines on the
Reuse of Bolts
OTHER NEW APPENDICES ARE:
Appendix L, ASME B16.5 Flange Bolting InformationTis
Appendix provides a handy look-up for the number and size of
bolts for all fange sizes (NPS) and Class combinations.
Appendix M, Washer Use Guidance and Purchase Specifcation
for Trough-Hardened Washers
Tis new guideline document was created to fll a need for a
through-hardened washer specifcation that suited bolted fange
joint applications for pressure vessels and piping (versus the ASTM
F-436 structural washer specifcation). Appendix M provides
guidance on service temperature limits for the diferent materials
listed. Both single use and multiple-use applications are covered.
Appendix O, Assembly Bolt Stress Determination
Te intent of this Appendix is to provide guidance for the
determination of an appropriate assembly bolt stress with due
consideration for integrity of each joint. Te detailed procedures
provided in this Appendix are intended for fange joints for which
controlled assembly methods are to be used. Provisions are made for
both a simple approach and for a joint component approach.
Appendix P, Guidance on Troubleshooting Flanged Joint
Leakage Incidents
Tis Appendix is intended to assist fanged joint troubleshooting
eforts by providing:
(a) an investigative and diagnostic evaluation guide to
characterize the joint in terms of its historical, operating, and
mechanical status
(b) a sample Flanged Joint Leak Report
(c) a checklist of fange design and acceptable practice
considerations
(d) a set of problem and potential solution diagnostic
troubleshooting tables.
A very useful sample fange joint leak report form is provided for
accurate feld documentation of the leakage under consideration.