API 579/ ASME FFS-1 Fitness for Service Part 1 (Level 1 & 2)

COURSE DESCRIPTION

Fitness-For-Service(FFS) is an essential guideline for a run-repair-replace decision-making process to help determine if pressurized equipment containing flaws that have been identified by inspection can continue to operate safely for certain period of time. The methods covered by FFS are suitable, compatible and in some cases required with and from major inspection codes and standards (i.e. ASME or API). Applicable to most types of pressurized equipment, piping and piping systems and storage tanks where flaws and damage or degradation has been detected or identified.

This 7-days advanced course provides guidance for conducting FFS assessments using methodologies as covered in the de-facto industry standard API 579/ ASME FFS-1, applicable to the pressurized equipment. The course has been adopted and revised to correspond to the latest edition of the code (June 2016), and covers both the main code body of knowledge (API 579-1/ ASME FFS-1 Fitness-For-Service) as well as illustrative implementation examples as given in API 579-2/ ASME FFS-2 Fitness-For-Service Example Problem Manual.

Detailed knowledge and understanding of the design and inspection codes is pre-requisite for attendance to this course. Such as ASME Sec. VIII Div.1, ASME Sec. VIII Div. 2, ASME Sec. 1, ASME B31.1, ASME B31.3, ASME API 650 and API 620

COURSE OBJECTIVE

• This training course covers API 579-1/ ASME FFS-1 with a focus on the Level 1 & 2 assessment procedures and their practical implementation and introduction into Level 3 assessments. The students should be able to complete by themselves in a confident manner at least Level 2 assessment ; coupled with strong design code knowledge and inspection experience.
• Discussion on damage mechanisms and the importance of identification, inspection techniques for flaw characterization, remaining life considerations, remediation methods and methods for life extension of damaged equipment.
• Students should understand background and logic behind assessment procedures and work out the selected examples from the API 579-2/ ASME FFS-2 Example Problem Manuals in a guided manner.
• The course will cover the assessment of all major problems covered in the FFS-1 and FFS-2 document - brittle fracture, general and local metal loss including pitting, crack-like flaws and blisters/ HIC, creep, as well as fire and mechanical damage.

COURSE OUTLINE

Day 1
Module 1: Introduction

• Construction Codes and Fitness-For-Service
• Fitness-For-Service Definition'
• Scope and basic key definitions and links
• Organization and Use, responsibilities and qualifications
• Definition of selected terms and key references

Module 2: Fitness-for-Service Engineering Assessment Procedures

• Fitness-For-Service and Continued Operation
• Organization by Flaw Type and Damage Mechanism
• FFS Assessment Procedure
• Applicability and Limitations of the FFS Assessment Procedures
• Introduction into level 1,2, and 3 Assessment
• Remaining Life Assessment - Remaining Life and Guidance on Remaining Life Determination
• Documentation

Module 2a: Fitness-for-Service engineering assessment procedure background skills and knowledge

• Damage Mechanisms
• Thickness, MAWP and Stress Equations for a FFS Assessment
• Stress Analysis Overview for a FFS Assessment
• Practical guidance on background skills applications - worked examples

Module 3: Assessment of Equipment for Brittle Fracture

• Evaluation of Resistance to BF and Avoidance of Catastrophic BF
• Critical Exposure Temperature (CET) and Minimum Allowable Temperature (MAT)
• Applicability and Limitation of the Procedure;
• Level 1 & 2 for different systems; alternative methods, introduction into level 3
• Remaining Life Assessment and Remediation; In-Service Monitoring; Documentation

Module 3a: Assessment of Existing Equipment for Brittle Fracture - Particle examples

• Pressure vessels in caustic service, Level 1
• Piping example, Level 2
• Own example(s) Level 1 and 2 decide when to apply

Day 2
Module 4: Assessment of General Metal Loss

• Assessment Procedures for General Metal Loss
• Level 1 & 2 assessment procedures, introduction into Level 3
• Remaining Life Assessment - thickness approach
• Remaining Life Assessment - MAWP Approach
• Remediation and In-Service Monitoring; Documentation

Module 5: Assessment of Local Metal Loss

• Assessment Procedures for Local Metal Loss; localized or general choice; Pitting Damage; Applicability and limitations of the procedure
• Limitations Based on Flaw Type;
• Level 1 & 2 assessment procedures, introduction into level 3
• Assessment of Blend Ground Areas for Crack-Like Flaw Removal
• Remaining life assessment - thickness approach
• Remaining life assessment - MAWP Approach
• Remediation and in-service monitoring; Documentation

Module 6: Assessment of Pitting Corrosion

• Assessment of Pitting Corrosion; Assessment of Blister Arrays
• Limitations Based on Flaw Type and Limitations Based on Temperature
• Level 1 & 2 assessment procedures, introduction into level 3
• Remaining life assessment - MAWP approach
• MAWP Procedure for Remaining Life Determination
• Remediation and in-service monitoring; Documentation

Module 6a: Assessment of Metal Loss - Practical Examples

• General Corrosion - Heat exchanger level 1
• General Corrosion - Pressure vessel level 1 and 2
• General Corrosion - Piping level 1 and 2
• General Corrosion - Own example(s); determine necessary level(s)
• Pressure vessel single localized corrosion area, level 1
• Pressure vessel with groove-like flaws, level 1 and 2
• Atmospheric tank with localized corrosion, level 1 and 2
• Elbow with localized corrosion, level 2
• Piping with pitting example, level 1 and level 2
• Pressure vessel with pitting at the bottom, level 2

Day 3
Module 7: Assessment of Crack-like Flaws

• Assessment Procedures for Crack-Like Flaws; ASME Sec. VIII Div.2
• Use of Assessment Procedures to Evaluate Brittle Fracture
• Level 1 & 2 Assessment Procedures, introduction into Level 3
• Remaining life assessment - Subcritical Crack Growth and Leak-Before-Break Analysis
• In-Service Monitoring - Monitoring of Subcritical Crack Growth; Validation of Monitoring Method
• Documentation - General; Assessment Procedure; Remediation Methods; In-Service Monitoring
• Compendium of Stress Intensity Factor Solutions
• Compendium of Reference Stress Solutions for Crack-Like Flaw

Module 7a: Assessment of hydrogen blisters, weld misalignment and shell distortions and Crack-like Flaws - Practical examples

• Worked example: pressure vessel with blisters inside and outside; level 1 and 2
• Worked example: Piping with peaking at the long seam weld; levels 1 and 2
• Worked example: Pressure vessel with crack-like flaw; level 1
• Worked example: Spherical pressure vessel with crack-like flaw; level 1
• Worked example: Cylindrical pressure vessel with crack-like flaw; level 1 and 2
• Worked example: piping with crack-like flaw on circumferential seam; level 1 and 2

Day 4
Module 8 - Assessment of Fatigue Damage

• Assessment Procedures for Fatigue Damage
• ASME Sec. VIII Div. 2; Use of Fatigue Curves in Performing Assessments
• Level 1 & 2 Assessment Procedures, introduction into level 3
• Remaining Life Assessment - Included in Level 2 and Level 3 Assessments; Loading Time History
• In-Service Monitoring
• Documentation

Module 9: Assessment of Components Operating in the Creep Range

• FFS Procedures and Temperature Limits; Remaining Life of Components with and without Crack-Like Flaws
• Assessment Techniques and Acceptance Criteria - Overview; Level 1 and 2 assessment
• Remaining Life Assessment - Overview; Creep Rupture Life; Creep-Fatigue Interaction
• Creep Crack Growth; Cree Buckling; Creep-Fatigue Assessment of Dissimilar Weld Joints
• In-Service Monitoring
• Documentation - General; Documentation for Life Assessment

Day 5
Module 9: Assessment of Components Operating in the Creep Range (continued)
Level 2 assessment

• Creep, creep-thermal fatigue and corrosion interaction at high temperatures
• Omega, Larson-Miler and other parametric approaches to creep life assessment
• Creep and Creep crack growth

Module 10: Assessment of hydrogen blisters and hydrogen damage associated with HIC and SOHIC

• Assessment Procedures for Hydrogen Blisters, HIC and SOHIC
• HIC and SOHIC Definition; Hydrogen Blistering Definition
• HIC, SOHC and Blistering Distinct Damage Types
• Level 1  2 assessment procedures, introduction into level 3
• Remaining life assessment - HIC and SOHIC Growth Rates; Blister Growth
• Remediation - Elimination of Hydrogen Charging; Controlling Hydrogen Charging; Venting of Blisters; Blend Grinding; Repair and Replacement of Damaged Material; NACE Standard SP0296-10
• In-service monitoring - Monitoring for Hydrogen Charging; Inspection Methods for Monitoring; Detection of HIC, SOHIC, or Blister Damage Growth; Documentation

Module 11 - Assessment of Laminations

• Assessment Procedures for Laminations; Definition of Laminations; Laminations in Hydrogen Charging Service
• Recommendations for Inspection Technique and Sizing Requirements
• Assessment Techniques and Acceptance Criteria - Overview; Level 1, 2 and 3 Assessment
• In-Service Monitoring
• Documentation

Day 6
Module 12: Assessment of weld misalignment and shell distortions

• Evaluation of Weld Misalignment and Shell Distortions; ASME Sec. VIII Div. 2
• Level 1 & 2 assessment procedures, introduction into level 3
• Remaining ife assessment - Categories - Metal Loss, Cyclic Loading, High Temperature Operation
• Special requirements for a Level 3 Assessment
• Remediation - Addition of Reinforcement; Correction of Tolerances by Mechanical Means
• In-service monitoring and Grove-Like and Crack-life Flaws; Documentation
• Practical examples

Module 13: Assessment of Dents, Gouges, & Dent-Gouge Combinations

• Assessment Procedures for Dents, Gouges and Dent-Gouge Combinations
• Assessment Procedures for LTAs, Grooves and Other Shell Distortions
• Level 1 & 2 assessment procedures, introduction into Level 3
• Remaining Life Assessments - Categories of Remaining Life Assessment; Requirement for a Level 3 Assessment
• Remediation - Flaw Severity and Evaluation of Material Condition; Reinforcement of Dents, Gouges and Dent-Gouge Combinations; Use of General Corrosion Remediation Methods
• In-Service Monitoring - Requirements for In-Service Monitoring;
• Documentation

Module 14: Assessment of Fire Damage

• Assessment of Fire Damage; Assessment of Process Upsets; Guidelines and Assessment Flowchart
• Recommendations for Inspection Techniques and Sizing Requirements
• Assessment Techniques and Acceptance Criteria - Overview; Level 1 and 2 assessment
• Remaining Life Assessment - Thinning and Crack-Life Flaw Damage; Creep Damage
• Remediation - Techniques; Need for Repair or Replacement
• In-Service Monitoring
• Documentation - General; Heat Exposure Zones; Record Retention

Day 7
Module 14a: Practical Examples Creep, Fire Damage, Dents, Gouges, and Dent-Gouge Combinations, Lamination and Fatigue Damage

• Practical example: Creep Damage - Short-term overheating of pressure vessel; level 1
• Practical example: Creep Damage - boiler/ heater tubing overheating; level 1 and level 2
• Practical example: Creep Damage - crack-like flaw; creep crack growth; level 2
• Practical example: Fire Damage - Partially fire exposed vessel damage; level 1
• Practical example: Fire Damage - Partially fire exposed vessel
  damage; level 2
• Practical example: Dent damage – pipeline; level 1 and level 2
• Practical example: Gouge damage – pipeline; level 1 and level 2
• Practical example: Lamination damage – pressure vessel shell
  lamination; level 1and level 2
• Practical example: Fatigue damage assessment – remaining life
  assessment based on operation data and cycle counting; Level 1
• Practical example: Fatigue damage – assessment of fatigue crack
  growth; level 1 and level 2

Module 15: Repetitorium

• 2-hour repetitorium of covered modules
• Exam preparation

Final Exam

Trainer's Profile
DR. DANIEL BALOS

MSc in Mechanical Engineering with the specialization in applicative IT and industrial management, PhD in application of data mining techniques on material behaviour modeling for high temperature components.

Almost 20 years of work in research and industrial projects, as well as training activities especially in risk-based inspections for power plants and refining industry. Participated or lead more than 20 EU funded projects, and participated in a number of national projects in the area of material research and education abroad.

In these projects, a vast understanding and knowledge about materials, material degradation mechanisms, inspection methods, risks has been accumulated. Project and risk management skills are proven in numerous projects in last 10 years. Sub-project leader and part of the management team for iNTeg-Risk project (2008-2013).

In the area of RBI, he is active last 15 years, starting with participation in the key EU project in the area - RIMAP (Risk based inspection and maintenance procedures for European industry) - work in development and implementation of RBI approach for power plants, work in CEN CWA 15740 (standardization initiative for RBI in Europe), developed and implemented tools for RBI assessment of refining equipment in various projects.

Participation in the implementation project of RBI for NIS Serbia, EnBW Germany, as well as MOL, Hungary, ESKOM in South Africa, QP in Qatar and SINOPEC in China. Teaching RBI techniques and holding courses in RBI for petrochemical and power industry since 2005, with successful courses delivered in Germany, the Netherlands, Serbia, Romania, and China.