Fitness for Service: Pressure Vessels, Tanks

and Piping System

DATE: 20 to 24 July 2014

PLACE: Copthorne Hotel – Dubai, UAE

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. Fitness-For-Service (FFS) assessments are quantitative engineering evaluations that

are performed to demonstrate the structural integrity of an in-service pressure equipment/component

containing a flaw or damage. In the year 2007 of June, 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 defector international standard for conducting FFS assessments. The

main deliverables from FFS assessments are improved plant integrity and reduced maintenance costs.

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.

In this programme you will learn:

1. Fundamental principles of fitness-for-service, their practical application through case histories, and a

step-by-step evaluation process for each type of degradation mechanism

2. 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

3. 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

PROGRAMME OBJECTIVES

1. Latest techniques to determine the fitness-for-service of operating tanks, vessels, piping systems and

pipelines; and make cost-effective run-repair-replace decisions based on the principles of API

recommended practice 579 "Fitness-for-Service"

2. Balanced approach between the fundamental technical principles of structural integrity, stress and

fracture analysis, and their practical application to field conditions

3. Provides the participants with the tools necessary to recognize and assess defects in pressure vessels,

storage tanks and piping

4. Presents and applies the fundamentals rules of the ASME code to operating equipment and systems

5. Introduces the participants to the practical application of the ASME and API rules for structural

integrity of static equipment and pipelines, and their use to assess remaining life

6. Applies API/ASME 579 "Fitness-for-Service" through practical examples to analyze degraded conditions

and make cost-effective repair or use-as-is decisions

7. Applies the step-by-step 3-level approach of API/ASME 579 to evaluate inspection results and

recognize potential failure modes

8. Technical basis for reliability-based (risk-based) evaluation of remaining life

9. Latest developments in defect assessment techniques, starting with simple rules (level 1) and

progressing to the more comprehensive evaluation techniques (level 3)

10. Participants will be able to evaluate the structural integrity of corroded or damaged equipment, and

assess their remaining life. Degradation mechanisms include: 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, and fire

damage

WHO SHOULD ATTEND

This training programme is intended for technical professionals, supervisors and managers responsible for

ensuring the integrity and cost-effective operation of in-service pressure equipment, storage tanks, piping

and pipelines throughout their life cycle including design, operation, and maintenance in the petroleum,

petrochemical, process and power industries:

1. Plant engineers and designers, corrosion and materials engineers, project engineers

2. Reliability and integrity supervisors and engineers including safeguarding/MOC engineers

3. Inspection engineers and inspectors responsible for monitoring and assessing the condition of

pressure equipment and piping systems

4. Maintenance and operations supervisors and engineers responsible for shutdown planning and

implementation, maintenance and repairs/alterations of pressure vessels, heat exchangers, storage

tanks, piping and pipelines

PRE-REQUISITE

This is an intensive and comprehensive course in which participants are drawn into active participation in

discussions and example solutions to enhance learning. Delegates should be familiar with pressurized

equipment and piping systems and will probably have a technical degree and should be conversant in

calculations using a scientific calculator. Delegates may bring with them a hard copy of API 579-1/ASME

FFS-1 2007 (although this is not essential). A scientific calculator will be provided.

ORGANIZATIONAL IMPACT

1. Take full advantage of the best industry practice of API/ASME 579 standard "Fitness-for-Service" to

avoid unnecessary shutdowns, replacements or repairs

2. Make cost-effective run-or-repair decisions for equipment in-service

3. Plan, repair or replace projects, where necessary, based on the timely fitness-for-service prediction of

remaining life of tanks, vessels, piping and pipelines

PERSONAL IMPACT

1. Opportunity to extend his/her expertise in equipment design, defect assessment, and equipment

integrity analysis

2. Equipped with the necessary step-by-step procedure, formulas, and examples to perform simple (level

1), and intermediate (level 2) quantitative evaluations of a degraded condition and make technically

sound and cost-effective run-or-repair decisions

3. The delegates will receive comprehensive programme notes that supplement the FFS standard,

including copies of all presentations slides and worked examples to use as a reference

4. Introduced to the latest developments in fitness-for-service rules and their application, as well as a

view of the future directions and developments in this important field

PROGRAMME OUTLINE

DAY 1 - Foundations of Fitness-For-Service Assessment

1. Introduction

a. Overview of the American Petroleum Institute (API) codes and standards

b. Overview of the American Society of Mechanical Engineers codes and standards with historical

background

2. Fitness For Service

3. Overview of API 579 contents, objectives and applications

4. How to apply API 579 for cost-effective run-or-repair decisions

5. Fitness-for-Service assessment procedure

6. An overview of what is new in the latest release

7. List of Parts and Annexes and examples of major Parts

8. PART 1 - Introduction

9. PART 2 - Fitness-For-Service Engineering Assessment Procedure

10. Structure and Contents of the FFS Standard

DAY 2 - Mechanical Integrity and Fitness for Service

1. Overview of Mechanical Integrity of pressure equipment & piping system

2. ANNEX A - Thickness, MAWP & Stress Equations for a FFS Assessment

a. Calculation of Min, MAWP (MFH) & Membrane Stress

b. Pressure Vessel & End Caps

c. Piping components & Boiler Tubes

3. ANNEX G - Damage Mechanisms

4. NDE techniques

5. PT, VT, MT, ET, UT, RT

6. Overview of Brittle Fracture Mechanism

7. Data Requirements

8. Assessment Techniques

9. Acceptance Criteria

10. PART 3 - Assessment of Existing Equipment for Brittle Fracture

DAY 3 - Metal Loss - Corrosion and Pitting

1. PART 4 - Assessment of General Metal Loss

a. Overview of Corrosion Mechanisms

b. Data Requirements

c. Assessment Techniques

d. Acceptance Criteria

e. Worked example

1. PART 5 - Assessment of Local Metal Loss

2. Overview of Local Metal Loss Mechanisms

3. Data Requirements

4. Assessment Techniques

5. Acceptance Criteria

6. Worked example

7. Overview of Pitting Corrosion Mechanisms

8. Data Requirements

9. Assessment Techniques

10. Acceptance Criteria

1. Cost Performance Indicators

2. Management Reports

DAY 3 - Metal Loss - Corrosion and Pitting

2. PART 4 - Assessment of General Metal Loss

a. Overview of Corrosion Mechanisms

b. Data Requirements

c. Assessment Techniques

d . Acceptance Criteria

e. Worked example

13. PART 5 - Assessment of Local Metal Loss

14. Overview of Local Metal Loss Mechanisms

15. Data Requirements

16. Assessment Techniques

17. Acceptance Criteria

18. Worked example

19. Overview of Pitting Corrosion Mechanisms

20. Data Requirements

21. Assessment Techniques

22. Acceptance Criteria

23. Worked example

24. PART 6 - Assessment of Pitting Corrosion

DAY 4 - Blisters and Local Damage

2. PART 7 - Hydrogen Blisters, HIC & SOHIC

a. Overview of Hydrogen Damage

b. Data Requirements

c. Assessment Techniques

d. Acceptance Criteria

14. PART 8 - Weld Misalignment & Shell Distortions

15. Overview of Weld Misalignment & Shell Distortions

16. Data Requirements

17. Assessment Techniques

18. Acceptance Criteria

19. Worked example

20. Overview of Fracture Mechanics

21. Elements of RSTRENG

22. Data Requirements

23. Assessment Techniques

24. Acceptance Criteria

25. Worked example

26. PART 9 - Assessment of Crack-Like Flaws

DAY 5 - Creep, Fire and Mecahnical Damage

2. PART 10 - Assessment of Components Operating in the Creep Range

a. Overview of Creep Damage Mechanisms

b. Data Requirements

c. Assessment Techniques

d. Acceptance Criteria

e. Worked Example

12. PART 11 - Assessment of Fire Damage

13. Overview of Fire Damage

14. Data Requirements

15. Assessment Techniques

16. Acceptance Criteria

17. Case study – Example of fire damage assessment

18. Overview of Mechanical Damage

19. Various software packages considered for FFS

20. PART 12 - Assessment Of Dents, Gouges, and Dent-Gouge Combinations

21. Software review

22. Overview and Wrap Up

COURSE LANGUAGE: English

TRAINING FEES: USD$4,450.00 (Four Thousand Four Hundred and Fifty US Dollars)

NOTE

To confirm your registration kindly complete the form below

Creative Regional Consultant and Training

P.O.BOX:88685 Dubai, UAE

Contact No: 00971 4295 9944

Fax no: 00971 4295 9200

Email us: alyaa@crcdubai.com

Website: www.creative-seminars.com

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Creative Regional Consultant and Training

P.O.BOX:88685 Dubai, UAE Contact No: 00971 4295 9944

Fax no: 00971 4295 9200

Email us: alyaa@crcdubai.com

Website: www.creative-seminars.com