API 579-1/ASME FFS-1 2007 Fitness-For-Service

ANNEX B3
HISTOGRAM DEVELOPMENT AND CYCLE COUNTING FOR FATIGUE
ANALYSIS
(NORMATIVE)
PART CONTENTS
B3.1
Scope............................................................................................................................ B3-2
B3.2
Definitions.................................................................................................................... B3-2
B3.3
Histogram Development............................................................................................. B3-2
B3.4
Cycle Counting Using The Rainflow Method ........................................................... B3-2
B3.4.1
Overview ................................................................................................................ B3-2
B3.4.2
Procedure for Histogram Development.............................................................. B3-3
B3.5
Cycle Counting Using Max-Min Cycle Counting Method........................................ B3-3
B3.5.1
Overview ................................................................................................................ B3-3
B3.5.2
Procedure for Histogram Development.............................................................. B3-3
B3.6
Nomenclature .............................................................................................................. B3-5

B3-1

API 579-1/ASME FFS-1 2007 Fitness-For-Service

B3.1

Scope

This Annex contains cycle counting procedures required to perform a fatigue assessment for irregular stress
or strain versus time histories. These procedures are used to break the loading history down into individual
cycles that can be evaluated using the fatigue assessment rules of Annex B1. Two cycle counting methods
are presented in this Annex. An alternative cycle counting method may be used if agreed to by the OwnerUser.
B3.2

Definitions

The definitions used in this Annex are shown below.

a)

Event The operating histogram may include one or more events that produce fatigue damage. Each
event consists of loading components specified at a number of time points over a time period and is
repeated a specified number of times. For example, an event may be the startup, shutdown, upset
condition, or any other cyclic action. The sequence of multiple events may be specified or random.

b)

Cycle A cycle is a relationship between stress and strain that is established by the specified loading at
a location in a vessel or component. More than one stress-strain cycle may be produced at a location,
either within an event or in transition between two events, and the accumulated fatigue damage of the
stress-strain cycles determines the adequacy for the specified operation at that location. This
determination shall be made with respect to the stabilized stress-strain cycle.

c)

Proportional Loading During constant amplitude loading, as the magnitudes of the applied stresses
vary with time, the size of Mohrs circle of stress also varies with time. In some cases, even though the
size of Mohrs circle varies during cyclic loading, if the orientation of the principal axes remains fixed, the
loading is called proportional. An example of proportional loading is a shaft subjected to in-phase
torsion and bending, where the ratio of axial and torsional stress remains constant during cycling.

d)

Non-Proportional Loading If the orientation of the principal axes are not fixed, but change orientation
during cyclic loading, the loading is called non-proportional. An example of non-proportional loading is a
shaft subjected to out-of-phase torsion and bending, where the ratio of axial and torsional stress varies
continuously during cycling.

e)

Peak The point at which the first derivative of the loading or stress histogram changes from positive to
negative.

f)

Valley The point at which the first derivative of the loading or stress histogram changes from negative
to positive.

B3.3

Histogram Development

The loading histogram should be determined in accordance with Annex B1.

B3.4
B3.4.1

Cycle Counting Using The Rainflow Method

Overview

The Rainflow Cycle Counting Method (ASTM Standard No. E1049) is recommended to determine the time
points representing individual cycles for the case of situations where the variation in time of loading, stress,
or strain can be represented by a single parameter. This cycle counting method is not applicable for nonproportional loading. Cycles counted with the Rainflow Method correspond to closed stress-strain hysteresis
loops, with each loop representing a cycle.

B3-2

API 579-1/ASME FFS-1 2007 Fitness-For-Service

B3.4.2

Procedure for Histogram Development

a)

STEP 1 Determine the sequence of peaks and valleys in the loading histogram. If multiple loadings
are applied, it may be necessary to determine the sequence of peaks and valleys using a stress
histogram. If the sequence of events is unknown, the worst case sequence should be chosen.

b)

STEP 2 Re-order the loading histogram to start and end at either the highest peak or lowest valley, so
that only full cycles are counted. Determine the sequence of peaks and valleys in the loading history.
Let X denote the range under consideration, and let Y denote the previous range adjacent to X .

c)

STEP 3 Read the next peak or valley. If out of data, go to STEP 8.

d)

STEP 4 If there are less than 3 points, go to STEP 3; If not, form ranges X and Y using the three most
recent peaks and valleys that have not been discarded.

e)

STEP 5 Compare the absolute values of ranges X and Y.

1)

If

X  Y go to STEP 3

2)

If

X t Y go to STEP 6

f)

STEP 6 Count range Y as one cycle; discard the peak and valley of Y . Record the time points and
loadings or component stresses, as applicable, at the starting and ending time points of the cycle.

g)

STEP 7 Return to STEP 4 and repeat STEPs 4 to 6 until no more time points with stress reversals
remain.

h)

STEP 8 Using the data recorded for the counted cycles perform fatigue assessment in accordance
with Annex B1.

B3.5

Cycle Counting Using Max-Min Cycle Counting Method

B3.5.1

Overview

The Max-Min Cycle Counting Method is recommended to determine the time points representing individual
cycles for the case of non-proportional loading. The cycle counting is performed by first constructing the
largest possible cycle, using the highest peak and lowest valley, followed by the second largest cycle, etc.,
until all peak counts are used.
B3.5.2
a)
b)

Procedure for Histogram Development

STEP 1 Determine the sequence of peaks and valleys in the loading history. If some events are
known to follow each other, group them together but otherwise arrange the random events in any order.
STEP 2 Calculate the elastic stress components

V ij

produced by the applied loading at every point in

time during each event at a selected location of a vessel. All stress components must be referred to the
same global coordinate system. The stress analysis must include peak stresses at local discontinuities.
c)
d)

STEP 3 Scan the interior points of each event and delete the time points at which none of the stress
components indicate reversals (peaks or valleys).
STEP 4 Using the stress histogram from STEP 2, determine the time point with the highest peak or
m

lowest valley. Designate the time point as t , and the stress components as
e)

V ij .

t is a peak in the stress histogram, determine the component stress range

m
between time point t and the next valley in the stress histogram. If time point t is a valley, determine
m
the component stress range between time point t and the next peak. Designate the next time point
n
n
as t , and the stress components as V ij . Calculate the stress component ranges and the von Mises
STEP 5 If time point
m

equivalent stress range between time points t and t .

B3-3

API 579-1/ASME FFS-1 2007 Fitness-For-Service

mn

mn

'V ij

V ij  nV ij

(B3.1)

2
2
mn
mn
mn
mn

1  'V 11  'V 22    'V 22  'V 33  

mn
mn
mn
mn
mn
2
2
2
2  'V  'V   6  'V  'V  'V 
33
11
12
23
13

'S range

0.5

(B3.2)

f)

STEP 6 Repeat STEP 5, for the current time point, t and the time point of the next peak or valley in
the sequence of the stress histogram. Repeat this process for every remaining time point in the stress
histogram.

g)

STEP 7 Determine the maximum von Mises equivalent stress range obtained in STEP 5 and record
m

the time points t and t that define the start and end points of the k
h)

STEP 8 Determine the event or events to which the time points

specified number of repetitions as

i)

th

cycle.

t and nt belong and record their

N and n N , respectively.

STEP 9 Determine the number of repetitions of the k

th

cycle.

1)

N  n N : Delete the time point mt from those considered in STEP 4, and reduce the number
n
n
n
m
of repetitions at time point t from N to ( N  N ) .

2)

If

3)

If

If

N ! n N : Delete the time point nt from those considered in STEP 4, and reduce the number of
m
m
m
n
repetitions at time point t from N to ( N  N ) .
m

N : Delete both time points mt and nt from those considered in STEP 4.

j)

STEP 10 Return to STEP 4 and repeat STEPs 4 to 10 until no more time points with stress reversals
remain.

k)

STEP 11 Using the data recorded for the counted cycles, perform fatigue assessment in accordance
with Annex B1 Note that an elastic-plastic fatigue assessment (see Annex B1, paragraph B1.5.4) may
be applied if

mn

'S range exceeds the yield point of the cyclic stress range-strain range curve of the

material.

B3-4

API 579-1/ASME FFS-1 2007 Fitness-For-Service

B3.6

Nomenclature
m

mn

'S range

von Mises equivalent stress range between time points

mn

'V ij

stress component range between time points t and t .

N
n
N

V ij
V ij

V ij

t
t
X

t and nt .

specified number of repetitions of the event associated with time point t .

n

specified number of repetitions of the event associated with time point t .

stress tensor at the point under evaluation.
stress tensor at the point under evaluation at time point
stress tensor at the point under evaluation at time point

m
n

t.

t.

time point under consideration with the highest peak or lowest valley.
m

time point under consideration that forms a range with time point t .
absolute value of the range (load or stress) under consideration using the Rainflow Cycle
Counting Method.
absolute value of the adjacent range (load or stress) to previous X using the Rainflow Cycle
Counting Method.

B3-5