Introduction to Fitness-For-Service (FFS)
API 579-1 / ASME FFS-1 2007
Eng. Ibrahem Maher
Program Outline
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In this program you will learn
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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.
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Fundamental principles of fitness-for-service, their practical application through a
step-by- step evaluation process for each type of degradation mechanism.
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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.
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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.
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
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A plant objective is to attain the maximum economic benefit and service life from existing
equipment without sacrificing integrity.
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This requires accurate assessment of the condition of the equipment and their suitability for
the actual service.
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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)
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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.
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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)
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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.
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API standards advocate proven, sound engineering and operating practices
and safe, interchangeable equipment and materials
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API standards include manuals, standards, specifications, recommended
practices, guidelines and technical reports.
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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
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Before 2000 there were no standards or Recommended Practices on
Fitness-For-Service Assessment
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The Materials Properties Council initiated activities in 1991 as a Group
Sponsored Project
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Original Scope - evaluate pressurized equipment in the refinery and
petrochemical industry. Then extended to other industries.
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First edition published in 2000 as API Recommended Practice API RP 579
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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?
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Determine if structural components, such as pressure vessels, tanks or
piping are safe and fit for continued operation
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Assess how reliable your assets will be over a set period of time – for
example, until your next planned shutdown
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Make informed decisions on whether to run, repair, re-rate, alter or retire
your equipment
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Assess the remaining life of your equipment to set future inspection
intervals and assist with your budgeting for capital cost.
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Reduce shutdown time and gain more effective remediation
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Gain expert recommendations on any necessary corrective action
Where is FFS Assessment applicable?
When is FFS Assessment needed?
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Asset lacks original design information or it may
have exceeded its useful life.
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Assets manufactured before 1987, equipment
operate at relatively low temperature - exposed
to self-refrigeration
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Decommissioned asset that may be used in a
different service
When is FFS Assessment needed?
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Equipment operating in either high temperature
and/or cyclic service
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Asset that have undergone any event that might
have affected its serviceability like: temperature
excursions, overloads, different feed/external
environment or a fire.
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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
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In June 2007 API and ASME produced a joint update of each society’s
version of FITNESS FOR SERVICE.
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The new standard is now called API 579-1/ASME FFS-1 2007 Fitness-ForService.
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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
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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
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Part 1: Introduction
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Part 2: Fitness-For Service Engineering Assessment Procedure
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Part 3: Assessment of Existing Equipment for Brittle Fracture
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Part 4: Assessment of General Metal Loss
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Part 5: Assessment of Local Metal loss
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Part 6: Assessment of Pitting Corrosion
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Part 7: Assessment of Hydrogen Blisters and Hydrogen Damage HIC & SOHIC
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Part 8: Assessment Of Weld Misalignment and Shell Distortions
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Part 9: Assessment of Crack-Like Flaws
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Part 10: Assessment of Components Operating in Creep Regime
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Part 11: Assessment of Fire Damage
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Part 12: Assessment of Dent, Gouges, and Dent-Gouge Combinations
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Part 13: Assessment of Laminations
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Annexes
List of annexes
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Annex A – Thickness, MAWP, and Stress Equations for a FFS Assessment
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Annex B – Stress Analysis Overview for a FFS Assessment
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Annex C – Compendium of Stress Intensity Factor Solutions
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Annex D – Compendium of Reference Stress Solutions
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Annex E – Residual Stresses in a FFS Evaluation
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Annex F – Material Properties for a FFS Assessment
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Annex G – Deterioration and Failure Modes
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Annex H – Validation
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Annex I – Glossary of Terms and Definitions
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Annex J – Currently Not Used
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Annex K – Crack Opening Areas
Degradation Mechanism
What happens to in-service equipment?
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Time dependent degradation
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Upset operating condition (Pressure, Temperature)
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Fluid - Material Interaction
What need to be done?
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Inspection (original fabrication and in-service flaws)
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Maintenance (including repairs and replacement)
Failure conditions and types of flaws
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Brittle fracture
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Fire damage
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Metal loss due to corrosion /erosion (general, local, and pitting)
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Hydrogen Induced Cracking damage (blisters, HIC, SOHIC)
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Geometrical irregularities (weld misalignment and distortion)
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Crack-like flaws (Amine, Ammonia, Carbonate cracking, …)
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Creep
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Dent and gouges
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Laminations
Levels of Assessment
Level 1
 Conservative screening
 Minimum amount of inspection or component information
 Plant inspection or engineering personnel
Level 2
 More detailed less conservative with more accurate results
 Inspection information
 Qualified engineering personnel
Level 3
 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
Fitness-for-Service assessment procedure
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Step 1 – Flaw/Condition Identification (Mode of Failure)
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Step 2 - Applicability and Limitations
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Step 3 - Data Requirements
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Step 4 - Assessment Techniques and Acceptance Criteria
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Step 5 - Remaining Life Evaluation
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Step 6 - Remediation
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Step 7 - In-Service Monitoring
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Step 8 - Documentation
Evaluation Methodology
Benefits
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Safe and reliable operation
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Reduce downtime by eliminating
unnecessary repairs
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Extra time to plan shutdown
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Reduce costs
Thank you for
attention