1. Introduction to Fitness-For-Service (FFS)
API / ASME FFS
Eng. Ibrahem Maher

2. 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

3. 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.

4. Day 1 Foundations of Fitness-for-service Assessment
Introduction
Fitness-For-Service assessment
API/ASME Standard API /ASME FFS-1
List of parts and annexes
Levels of Assessment
Fitness-for-Service assessment procedure
Benefits

5. 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

6. 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.

7. 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.

8. 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

9. 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 Second Edition of document ASME/API Standard published in 2007 (API /ASME FFS-1). Example problems published in 2009 (API /ASME FFS-2)

10. 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

11. Where is FFS Assessment applicable?

12. 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

13. 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.

14. 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 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.

15. 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

16. 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

17. 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

18. Degradation Mechanism

19. 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)

20. 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)

21. 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

22. 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

23. Evaluation Methodology

24. Benefits Safe and reliable operation
Reduce downtime by eliminating unnecessary repairs
Extra time to plan shutdown
Reduce costs

25. Thank you for attention