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Introduction to Fitness-For-Service (FFS)
API 579-1 / ASME FFS-1 2007
Eng. Ibrahem Maher
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Program Outline DAY 1 - Foundations of Fitness-For-Service
Assessment
DAY 2 - Mechanical Integrit and Fitness for Service
DAY ! - Metal "oss - #orrosion and $itting
DAY % - &listers and "ocal Damage
DAY ' - #ree() Fire and Mechanical Damage
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In this program you will learn *he (artici(ant in this
integrated and com(rehensive course +ill learn to a((l the
rules of the A$I,ASME ' standard /Fitness-for-Service/ to
evaluate the integrit
and remaining life of (ressure vessels) storage tan0s) (i(ing
sstems and (i(elines)
to ma0e cost effective run-re(air-re(lace decisions) and select
the a((ro(riate re(air
o(tions.
Fundamental (rinci(les of fitness-for-service) their (ractical
a((lication through a
ste(-b- ste( evaluation (rocess for each t(e of degradation
mechanism. &asic design of (ressure vessels) (i(ing and storage
tan0s) fundamental (rinci(les
of com(onent integrit) a((lication of the ASME code rules)
material (ro(erties of
strength and toughness) and the introduction to stress and
fracture mechanics.
A revie+ of degradation mechanisms and the a((lication of
A$I,ASME ' to
brittle fracture) general metal loss) local +all thinning)
(itting) blisters and
laminations) mechanical defects dents) gouges) misalignment) and
distortion)
crac0-li0e fla+s stress corrosion crac0ing) +eld fla+s)
crac0-li0e defects) fatigue)
3I# 4 S53I# and fire damage.
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Da 1 Foundations of Fitness-for-service Assessment
Fitness-For-Service assessment
API/ASME Standard API !"-# /ASME FFS-#
Fitness-for-Service assessment procedure
Introduction
$ist of parts and anne%es
$evels of Assessment
&enefits
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Introduction
A (lant ob6ective is to attain the ma7imum economic benefit and
service life from e7isting
e8ui(ment +ithout sacrificing integrit. *his re8uires accurate
assessment of the condition of the e8ui(ment and their suitabilit
for
the actual service.
*here are a lot of standards organi9ations such as:
A;SI - American ;ational Standards InstituteAPI - American
Petroleum Institute
ASME - American Society of Mechanical Engineers
AS$E - American Societ of $lumbing Engineers
AS*M International - American Societ for *esting and
Material
&Si - &ritish Standards institute
DI; - Deutsches Institut f
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American Society of Mechanical Engineers 'ASME(
ASME is an engineering societ) a standards organi9ation) a
research and develo(ment organi9ation) a (rovider of
training
and education) and a non(rofit organi9ation. Founded as an
engineering societ focused on mechanical engineering in
;orth America.
It (roduces a((ro7imatel =>> codes and standards)
covering
man technical areas) such as boiler com(onents) elevators)
measurement of fluid flo+ in closed conduits) cranes) hand
tools) fasteners) and machine tools.
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American Petroleum Institute 'API(
*he American $etroleum Institute A$I maintains more than
'>>
documents that a((l to man segments of the oil and gas industr -
from
drill bits to environmental (rotection.
A$I standards advocate (roven) sound engineering and o(erating
(ractices
and safe) interchangeable e8ui(ment and materials
A$I standards include manuals) standards) s(ecifications)
recommended
(ractices) guidelines and technical re(orts.
A$I standards cover: Environmental and safet) E7(loration
and
(roduction) Ins(ection measurement) $etroleum measurement)
?efining)
*rans(ortation) mar0eting 4 safet.
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Fitness-For-Service assessment
An industr term used to @uantitative engineering evaluation
to
determine if an in-service e8ui(ment is Safe and ?eliable to
o(erate at S(ecific #onditions during a Determined *ime
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)istory
&efore 2>>> there +ere no standards or ?ecommended
$ractices on
Fitness-For-Service Assessment *he Materials $ro(erties #ouncil
initiated activities in 11 as a rou(
S(onsored $ro6ect
5riginal Sco(e - evaluate (ressuri9ed e8ui(ment in the refiner
and
(etrochemical industr. *hen e7tended to other
industries.
First edition (ublished in 2>>> as A$I ?ecommended
$ractice A$I ?$ '
ASME,A$I Boint #ommittee start activities in 2>>!. Second
Edition of
document ASME,A$I Standard (ublished in 2>> A$I '-
1,ASME
FFS-1. E7am(le (roblems (ublished in 2>> A$I '- 2,ASME
FFS-2
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*hy use a fitness for service assessment?
Determine if structural com(onents) such as (ressure vessels)
tan0s or
(i(ing are safe and fit for continued o(eration
Assess ho+ reliable our assets +ill be over a set (eriod of time
C for
e7am(le) until our ne7t (lanned shutdo+n
Ma0e informed decisions on +hether to run) re(air) re-rate)
alter or retire
our e8ui(ment
Assess the remaining life of our e8ui(ment to set future
ins(ection
intervals and assist +ith our budgeting for ca(ital cost.
?educe shutdo+n time and gain more effective remediation
ain e7(ert recommendations on an necessar corrective action
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*here is FFS Assessment applica+le?
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*hen is FFS Assessment needed?
Asset lac0s original design information or it ma
have e7ceeded its useful life. Assets manufactured before 1)
e8ui(ment
o(erate at relativel lo+ tem(erature - e7(osed
to self-refrigeration
Decommissioned asset that ma be used in a
different service
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*hen is FFS Assessment needed?
E8ui(ment o(erating in either high tem(erature
and,or cclic service
Asset that have undergone an event that might
have affected its serviceabilit li0e: tem(erature
e7cursions) overloads) different feed,e7ternal
environment or a fire.
Ins(ection findings revealed a condition that
ma im(act the future o(eration of the asset)
such as metal loss) distortion misalignment) out
of roundness) bulges or dents) laminations)
crac0ing or blisters) etc.
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API/ASME Standard API !"-# /ASME FFS-
# In Bune 2>> A$I and ASME (roduced a 6oint u(date of each
societs
version of FI*;ESS F5? SE?I#E.
*he ne+ standard is no+ called A$I '-1,ASME FFS-1 2>>
Fitness-
For-Service.
It has become the de facto international standard for conducting
FFS
assessments. *he main deliverables from FFS assessments are
im(roved
(lant integrit and reduced maintenance costs.
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API/ASME Standard API !"-# /ASME FFS-
# Assessment or re-rating of com(onents designed and constructed
to:
G ASME &4$ #odes Section III Division 1 4 2
G ASME #odes Section I
G ASME &!1.! $i(ing #ode
G ASME &!1.1 $i(ing #ode
G A$I Standards:
G A$I ='>
G A$I =2>
G 5ther recogni9ed codes and standards) including International
Standards
revie+ attributes,com(are to A$I 4 ASME codes
G Methods and (rocedures intended to su((lement A$I '1>) A$I
'>) and
A$I ='!
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$ist of parts $art 1: Introduction
$art 2: Fitness-For Service Engineering Assessment $rocedure
$art !: Assessment of E7isting E8ui(ment for &rittle
Fracture
$art %: Assessment of eneral Metal "oss
$art ': Assessment of "ocal Metal loss
$art =: Assessment of $itting #orrosion
$art : Assessment of 3drogen &listers and 3drogen Damage 3I#
4 S53I#
$art : Assessment 5f Held Misalignment and Shell Distortions
$art : Assessment of #rac0-"i0e Fla+s
$art 1>: Assessment of #om(onents 5(erating in #ree(
?egime
$art 11: Assessment of Fire Damage $art 12: Assessment of Dent)
ouges) and Dent-ouge #ombinations
$art 1!: Assessment of "aminations
Anne7es
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$ist of anne%es Anne7 A C *hic0ness) MAH$) and Stress E8uations
for a FFS Assessment
Anne7 & C Stress Analsis 5vervie+ for a FFS Assessment Anne7
# C #om(endium of Stress Intensit Factor Solutions
Anne7 D C #om(endium of ?eference Stress Solutions
Anne7 E C ?esidual Stresses in a FFS Evaluation
Anne7 F C Material $ro(erties for a FFS Assessment
Anne7 C Deterioration and Failure Modes
Anne7 3 C alidation
Anne7 I C lossar of *erms and Definitions Anne7 B C #urrentl ;ot
sed
Anne7 J C #rac0 5(ening Areas
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,egradation Mechanism
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*hat happens to in-service euipment?
*ime de(endent degradation
(set o(erating condition $ressure) *em(erature
Fluid - Material Interaction
What need to be done?
Ins(ection original fabrication and in-service fla+s
Maintenance including re(airs and re(lacement
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Failure conditions and types of flaws
&rittle fracture
Fire damage
Metal loss due to corrosion ,erosion general) local) and
(itting
3drogen Induced #rac0ing damage blisters) 3I#) S53I#
eometrical irregularities +eld misalignment and distortion
#rac0-li0e fla+s Amine) Ammonia) #arbonate crac0ing) K
#ree(
Dent and gouges
"aminations
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$evels of Assessment
"evel 1
#onservative screening
Minimum amount of ins(ection or com(onent information $lant
ins(ection or engineering (ersonnel
More detailed less conservative +ith more accurate results
Ins(ection information @ualified engineering (ersonnel
*he most detailed evaluation *he most detailed ins(ection and
com(onent information ?ecommended analsis (rocedures based on
material testing
and , or numerical analsis techni8ues such as the finite
element method $ersonnel +ith e7(ertise in #om(le7 FFS
Assessments
"evel 2
"evel !
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Fitness-for-Service assessment procedure
Ste( 1 C Fla+,#ondition Identification Mode of Failure
Ste( 2 - A((licabilit and "imitations
Ste( ! - Data ?e8uirements
Ste( % - Assessment *echni8ues and Acce(tance #riteria
Ste( ' - ?emaining "ife Evaluation
Ste( = - ?emediation
Ste( - In-Service Monitoring
Ste( - Documentation
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Evaluation Methodology
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&enefits
Safe and reliable o(eration
?educe do+ntime b eliminating
unnecessar re(airs
E7tra time to (lan shutdo+n
?educe costs
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Thank you for
attention
