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 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 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 stress oriented HIC (SOHIC)

Levels of Assessment Level 1 Level 2 Level 3 Conservative screening Minimum amount of inspection or component information Plant inspection or engineering personnel Level 1 More detailed less conservative with more accurate results Inspection information Qualified engineering personnel Level 2 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 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