API 579-1 ASME FFS-1: Fitness for Service: Pressure Vessels, Tanks and Piping Systems

Introduction

A plant objective is to attain the maximum economic benefit and service life from existing equipment without sacrificing integrity. This requires an accurate assessment of the condition of the equipment and their suitability for the actual service. Fitness-For-Service (FFS) assessments are quantitative engineering evaluations that are performed to demonstrate the structural integrity of an in-service pressure equipment/component containing a flaw or damage. 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 defect international standard for conducting FFS assessments. The main deliverables from FFS assessments are improved plant integrity and reduced maintenance costs.

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. In this program you will learn:

• Fundamental principles of fitness-for-service, their practical application through case histories, and a step-by-step evaluation process for each type of degradation mechanism
• The 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.

Objectives

• Latest techniques to determine the fitness-for-service of operating tanks, vessels, piping systems, and pipelines; and make cost-effective run-repair-replace decisions based on the principles of API recommended practice 579 "Fitness-for-Service"
• A balanced approach between the fundamental technical principles of structural integrity, stress and fracture analysis, and their practical application to field conditions
• Provides the participants with the tools necessary to recognize and assess defects in pressure vessels, storage tanks, and piping
• Presents and applies the fundamentals rules of the ASME code to operating equipment and systems
• Introduces the participants to the practical application of the ASME and API rules for the structural integrity of static equipment and pipelines, and their use to assess the remaining life
• Applies API/ASME 579 "Fitness-for-Service" through practical examples to analyze degraded conditions and make a cost-effective repair or use-as-is decisions
• Applies the step-by-step 3-level approach of API/ASME 579 to evaluate inspection results and recognize potential failure modes
• The technical basis for reliability-based (risk-based) evaluation of remaining life
• Latest developments in defect assessment techniques, starting with simple rules (level 1) and progressing to the more comprehensive evaluation techniques (level 3)
• Participants will be able to evaluate the structural integrity of corroded or damaged equipment and assess their remaining life. Degradation mechanisms include: 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, and fire damage  

PRE-REQUISITE

This is an intensive and comprehensive course in which participants are drawn into active participation in discussions and example solutions to enhance learning. Delegates should be familiar with pressurized equipment and piping systems and will probably have a technical degree and should be conversant in calculations using a scientific calculator.  Delegates may bring with them a hard copy of API 579-1/ASME FFS-1 2007 (although this is not essential).  A scientific calculator will be provided. 

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This training program is intended for technical professionals, supervisors, and managers responsible for ensuring the integrity and cost-effective operation of in-service pressure equipment, storage tanks, piping and pipelines throughout their life cycle including design, operation, and maintenance in the petroleum, petrochemical, process and power industries:

• Plant engineers and designers, corrosion and materials engineers, project engineers
• Reliability and integrity supervisors and engineers including safeguarding/MOC engineers
• Inspection engineers and inspectors responsible for monitoring and assessing the condition of pressure equipment and piping systems
• Maintenance and operations supervisors and engineers responsible for shutdown planning and implementation, maintenance and repairs/alterations of pressure vessels, heat exchangers, storage tanks, piping, and pipelines

Course Outline

DAY 1 - Foundations of Fitness-For-Service Assessment

• Introduction
  • Overview of API codes and standards
  • Overview of ASME codes and standards with historical background
• Overview of Mechanical Integrity of Pressure Vessels & Piping System
• Fitness For Service
• Overview of API 579 contents, objectives and applications
• How to apply API 579 for cost-effective run-or-repair decisions
• Fitness-for-Service Assessment procedure
• An overview of what is new in the latest release
• List of Parts and Annexes and examples of major Parts
• PART 1 - Introduction
• PART 2 - Fitness-For-Service Engineering Assessment Procedure
•  Structure and Contents of the FFS Standard

DAY 2 - Background of Stress Calculations for FSS Assessment

• ANNEX A - Thickness, MAWP & Stress Equations for a FFS Assessment
  • Calculation of tmin, MAWP (MFH) & Membrane Stress
  • Pressure Vessel & Boiler Components: Shells, Heads, Nozzles
  • Piping components & Boiler Tubes
  • Storage Tanks
• ANNEX G - Damage Mechanisms
• Deterioration and Failure Modes
• Pre-Service and In-Service Deficiencies
• PT, VT, MT, ET, UT, RT
• Overview of Brittle Fracture Mechanism
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• NDE (NDT) Techniques
• PART 3 - Assessment of Existing Equipment for Brittle Fracture

DAY 3 - Metal Loss, Corrosion, Pitting and Blisters

• PART 4 - Assessment of General Metal Loss
  • Overview of Corrosion Mechanisms
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation
  • Worked example
• PART 5 - Assessment of Local Metal Loss
• Overview of Local Metal Loss Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• Overview of Pitting Corrosion Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• Overview of Hydrogen Damage
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• PART 6 - Assessment of Pitting Corrosion
• PART 7 - Hydrogen Blisters, HIC & SOHIC

DAY 4 - Local Damage, Cracks, Creep

• PART 8 - Weld Misalignment & Shell Distortions
  • Overview of Weld Misalignment & Shell Distortions
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation
  • Worked example
• PART 9 - Assessment of Crack-Like Flaws
• Overview of Fracture Mechanics
• Elements of RSTRENG
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation  
• Worked example
• Overview of Creep Damage Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• PART 10 - Assessment of Components Operating in the Creep Range

DAY 5 - Fire and Mechanical Damage

• PART 11 - Assessment of Fire Damage
  • Overview of Fire Damage
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation
  • Case study – Example of fire damage assessment
• PART 12 - Assessment of Dents, Gouges, and Dent-Gouge Combinations
• Overview of Mechanical Damage
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Overview of Laminations and their Role
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Various software packages considered for FFS
• PART 13 - Assessment of Laminations
• Software review