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 fr 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 societys

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-
Assessment or re-rating of components designed and constructed to:
1
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
Conservative screening
Level 1 Minimum amount of inspection or component information
Plant inspection or engineering personnel

More detailed less conservative with more accurate results

Level 2 Inspection information
Qualified engineering personnel

The most detailed evaluation

The most detailed inspection and component information
Recommended analysis procedures based on material testing
Level 3 and / or numerical analysis techniques such as the finite
element method
Personnel with expertise in Complex FFS Assessments
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