Introduction to Fitness-For-Service (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

Fitness-For-Service assessment

API/ASME Standard API 579-1 /ASME FFS-1

Fitness-for-Service assessment procedure

Introduction

List of parts and annexes

Levels of Assessment

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 für 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 society’s

version of FITNESS FOR SERVICE.

The new standard is now called API 579-1/ASME FFS-1 2007 Fitness-

For-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-1 Assessment or re-rating of components designed and constructed to:

• 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

More detailed less conservative with more accurate results Inspection information Qualified engineering personnel

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

Level 2

Level 3

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