Introduction to Fitness-ForService (FFS)

API 579-1 / ASME FFS-1 2007

Eng. Ibrahem Maher

Program Outline

DAY 1 - Foundations of Fitness-For-Service Assessment

DAY 2 - Mechanical Integrity and Fitness for Service

DAY 3 - Metal Loss - Corrosion and Pitting

DAY 4 - Blisters and Local Damage

DAY 5 - Creep, Fire and Mechanical Damage

In this program you will learn

The participant in this integrated and comprehensive course will learn to apply the
rules of the API/ASME 579 standard "Fitness-for-Service" to evaluate the integrity
and remaining life of pressure vessels, storage tanks, piping systems and pipelines,
to make cost effective run-repair-replace decisions, and select the appropriate repair
options.

Fundamental principles of fitness-for-service, their practical application through a

step-by- step evaluation process for each type of degradation mechanism.

Basic design of pressure vessels, piping and storage tanks, fundamental principles
of component integrity, application of the ASME code rules, material properties of
strength and toughness, and the introduction to stress and fracture mechanics.

A review of degradation mechanisms and the application of API/ASME 579 to

brittle fracture, general metal loss, local wall thinning, pitting, blisters and
laminations, mechanical defects (dents, gouges, misalignment, and distortion),
crack-like flaws (stress corrosion cracking, weld flaws, crack-like defects), fatigue,
HIC & SOHIC and fire damage.

Day 1 Foundations of Fitness-for-service Assessment

Introduction
Fitness-For-Service assessment
API/ASME Standard API 579-1 /ASME FFS-1
List of parts and annexes
Levels of Assessment
Fitness-for-Service assessment procedure
Benefits

Introduction

A plant objective is to attain the maximum economic benefit and service life from existing
equipment without sacrificing integrity.

This requires accurate assessment of the condition of the equipment and their suitability for
the actual service.

There are a lot of standards organizations such as:

ANSI - American National Standards Institute
API - American Petroleum Institute
ASME - American Society of Mechanical Engineers
ASPE - American Society of Plumbing Engineers
ASTM International - American Society for Testing and Material
BSi - British Standards institute
DIN - Deutsches Institut fr Normung

American Society of Mechanical Engineers (ASME)

ASME is an engineering society, a standards organization, a

research and development organization, a provider of training
and education, and a nonprofit organization. Founded as an
engineering society focused on mechanical engineering in
North America.

It produces approximately 600 codes and standards, covering

many technical areas, such as boiler components, elevators,
measurement of fluid flow in closed conduits, cranes, hand
tools, fasteners, and machine tools.

American Petroleum Institute (API)

The American Petroleum Institute (API) maintains more than 500

documents that apply to many segments of the oil and gas industry - from
drill bits to environmental protection.

API standards advocate proven, sound engineering and operating practices

and safe, interchangeable equipment and materials

API standards include manuals, standards, specifications, recommended

practices, guidelines and technical reports.

API standards cover: Environmental and safety, Exploration and

production, Inspection measurement, Petroleum measurement, Refining,
Transportation, marketing & safety.

Fitness-For-Service assessment

An industry term used to Quantitative engineering evaluation to

determine if an in-service equipment is Safe and Reliable to
operate at Specific Conditions during a Determined Time

History

Before 2000 there were no standards or Recommended Practices on

Fitness-For-Service Assessment

The Materials Properties Council initiated activities in 1991 as a Group

Sponsored Project

Original Scope - evaluate pressurized equipment in the refinery and

petrochemical industry. Then extended to other industries.

First edition published in 2000 as API Recommended Practice API RP 579

ASME/API Joint Committee start activities in 2003. Second Edition of

document ASME/API Standard published in 2007 (API 579- 1/ASME
FFS-1). Example problems published in 2009 (API 579- 2/ASME FFS-2)

? Why use a fitness for service assessment

Determine if structural components, such as pressure vessels, tanks or

piping are safe and fit for continued operation

Assess how reliable your assets will be over a set period of time for
example, until your next planned shutdown

Make informed decisions on whether to run, repair, re-rate, alter or retire

your equipment

Assess the remaining life of your equipment to set future inspection

intervals and assist with your budgeting for capital cost.

Reduce shutdown time and gain more effective remediation

Gain expert recommendations on any necessary corrective action

?Where is FFS Assessment applicable

?When is FFS Assessment needed

Asset lacks original design information or it may

have exceeded its useful life.

Assets manufactured before 1987, equipment

operate at relatively low temperature - exposed
to self-refrigeration

Decommissioned asset that may be used in a

different service

?When is FFS Assessment needed

Equipment operating in either high temperature

and/or cyclic service

Asset that have undergone any event that might

have affected its serviceability like: temperature
excursions, overloads, different feed/external
environment or a fire.

Inspection findings revealed a condition that

may impact the future operation of the asset,
such as metal loss, distortion (misalignment, out
of roundness, bulges or dents), laminations,
cracking or blisters, etc.

API/ASME Standard API 579-1 /ASME FFS

1 In June 2007 API and ASME produced a joint update of each societys
version of FITNESS FOR SERVICE.

The new standard is now called API 579-1/ASME FFS-1 2007 FitnessFor-Service.

It has become the de facto international standard for conducting FFS

assessments. The main deliverables from FFS assessments are improved
plant integrity and reduced maintenance costs.

API/ASME Standard API 579-1 /ASME FFS Assessment or re-rating of components designed and constructed to:
1
ASME B&PV Codes Section VIII Division 1 & 2
ASME Codes Section I
ASME B31.3 Piping Code
ASME B31.1 Piping Code
API Standards:
API 650
API 620
Other recognized codes and standards, including International Standards
(review attributes/compare to API & ASME codes)
Methods and procedures intended to supplement API 510, API 570, and
API 653

List of parts

Part 1: Introduction

Part 2: Fitness-For Service Engineering Assessment Procedure

Part 3: Assessment of Existing Equipment for Brittle Fracture

Part 4: Assessment of General Metal Loss

Part 5: Assessment of Local Metal loss

Part 6: Assessment of Pitting Corrosion

Part 7: Assessment of Hydrogen Blisters and Hydrogen Damage HIC & SOHIC

Part 8: Assessment Of Weld Misalignment and Shell Distortions

Part 9: Assessment of Crack-Like Flaws

Part 10: Assessment of Components Operating in Creep Regime

Part 11: Assessment of Fire Damage

Part 12: Assessment of Dent, Gouges, and Dent-Gouge Combinations

Part 13: Assessment of Laminations

Annexes

List of annexes

Annex A Thickness, MAWP, and Stress Equations for a FFS Assessment

Annex B Stress Analysis Overview for a FFS Assessment

Annex C Compendium of Stress Intensity Factor Solutions

Annex D Compendium of Reference Stress Solutions

Annex E Residual Stresses in a FFS Evaluation

Annex F Material Properties for a FFS Assessment

Annex G Deterioration and Failure Modes

Annex H Validation

Annex I Glossary of Terms and Definitions

Annex J Currently Not Used

Annex K Crack Opening Areas

Degradation Mechanism

?What happens to in-service equipment

Time dependent degradation

Upset operating condition (Pressure, Temperature)

Fluid - Material Interaction

?What need to be done

Inspection (original fabrication and in-service flaws)

Maintenance (including repairs and replacement)

Failure conditions and types of flaws

Brittle fracture

Fire damage

Metal loss due to corrosion /erosion (general, local, and pitting)

Hydrogen Induced Cracking damage (blisters, HIC, SOHIC)

Geometrical irregularities (weld misalignment and distortion)

Crack-like flaws (Amine, Ammonia, Carbonate cracking, )

Creep

Dent and gouges

Laminations

Levels of Assessment
Level 1

Conservative screening
Minimum amount of inspection or component information
Plant inspection or engineering personnel

Level 2

More detailed less conservative with more accurate results

Inspection information
Qualified engineering personnel

Level 3

The most detailed evaluation

The most detailed inspection and component information
Recommended analysis procedures based on material testing
and / or numerical analysis techniques such as the finite
element method
Personnel with expertise in Complex FFS Assessments

Fitness-for-Service assessment procedure

Step 1 Flaw/Condition Identification (Mode of Failure)

Step 2 - Applicability and Limitations

Step 3 - Data Requirements

Step 4 - Assessment Techniques and Acceptance Criteria

Step 5 - Remaining Life Evaluation

Step 6 - Remediation

Step 7 - In-Service Monitoring

Step 8 - Documentation

Evaluation Methodology

Benefits

Safe and reliable operation

Reduce downtime by eliminating

unnecessary repairs

Extra time to plan shutdown

Reduce costs

Thank you for

attention