Introduction to Fitness-For-

Service (FFS) Assessment Using

API/ASME Standard API 579-1 /
ASME FFS-1

Webinar Series
April 22, 2010

LLOYD’S REGISTER CAPSTONE

 Overview

• Definition of Fitness-For-Service (FFS) assessment

• Where is Fitness-For-Service assessment applicable?
• When is FFS assessment needed?
• Background on FFS standards
• Scope of FFS assessments per API/ASME Standard API 579-1 /ASME
FFS-1
• FFS methodology per API/ASME Standard API 579-1 /ASME FFS-1
• Evaluation techniques
• Benefits

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Definition of Fitness-For-Service (FFS)
Assessment

Quantitative engineering evaluation

to determine if an in-
in-service
equipment is Safe and Reliable to
operate at Specific Conditions during
a Determined Time

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Where is FFS Assessment applicable?

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 When is FFS Assessment needed?

• Asset lacks original design information or it may have exceeded

its useful life

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 When is FFS Assessment needed?

• Assets manufactured before 1987, equipment operate at

relatively low temperature - exposed to self-refrigeration

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 When is FFS Assessment needed?

• Decommissioned asset that may be used in a different service

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 When is FFS Assessment needed?

• Equipment operating in either high temperature and/or cyclic

service

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 When is FFS Assessment needed?
• Asset that have undergone any event that might have affected
its serviceability like: temperature excursions, overloads,
different feed/external environment or a fire.

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 When is FFS Assessment needed?
• 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.

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Fitness-For-Service Background

• 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)

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Scope of FFS Assessment per API/ASME Standard
API 579-1 / ASME FFS-1

• 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

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Scope of FFS Assessments

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)

Guidelines to make run-repair-replace decisions of

in-service equipment are required

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Scope of FFS Assessments

Failure conditions and types of flaws

➧ Brittle fracture
➧ Fire damage
➧ Metal loss due to corrosion /
erosion (general, local, and pitting)
➧ HIC damage (blisters, HIC, SOHIC)
➧ Geometrical irregularities (weld i Amine cracking
misalignment and distortion) i Ammonia cracking
➧ Crack-like flaws i Carbonate cracking
➧ Creep i Hydrogen damage (H2S, HF)
➧ Dent and gouges i Hydrogen attack
➧ Laminations i Caustic cracking in SS
i Chloride cracking in SS
i Polythionic cracking in SS

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Scope of Assessments

API 579-1 / ASME FFS 1 content (2nd Edition)

♦ Part 1:
1 Introduction
♦ Part 2:
2 Fitness-For Service Engineering Assessment Procedure
♦ Part 3:
3 Assessment of Existing Equipment for Brittle Fracture
♦ Part 4:
4 Assessment of General Metal Loss
♦ Part 5:
5 Assessment of Local Metal loss
♦ Part 6:
6 Assessment of Pitting Corrosion
♦ Part 7:
7 Assessment of Hydrogen Blisters and Hydrogen Damage HIC & SOHIC
♦ Part 8:
8 Assessment Of Weld Misalignment and Shell Distortions
♦ Part 9:
9 Assessment of Crack-Like Flaws
♦ Part 10:
10 Assessment of Components Operating in Creep Regime
♦ Part 11:
11 Assessment of Fire Damage
♦ Part 12:
12 Assessment of Dent, Gouges, and Dent-Gouge Combinations
♦ Part 13:
13 Assessment of Laminations
♦ Annexes

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Scope of Assessments
API 579-1 / ASME FFS 1 content (2nd Edition)

Degradation
Mechanism

Brittle Corrosion/ Crack-like Fire Creep Mechanical

Fracture Erosion Flaw Damage Damage Damage

Part 3 Part 4 Part 9 Part 11 Part 10 Part 5

Part 9 Part 5 Part 4 Part 9 Part 8
Part 6 Part 5 Part 9
Part 7 Part 8 Part 12
Part 9 Part 13
Part 10

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Evaluation Techniques and Derivable

Assessment Levels

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

Level 3
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

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Evaluation Techniques and Derivable

General Assessment Procedure / Steps

✔ 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

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Evaluation Techniques

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Lloyd’s Register Capstone FFS Assessment
Material Testing Simulations

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Benefits

* Safe and reliable operation

* Reduce downtime by eliminating
unnecessary repairs
* Extra time to plan shutdown
* Reduce costs

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 FFS Webinar Series

* Assessment of aging equipment using actual

material properties
* Brittle fracture assessment
* Assessment of fire damage
* Creep damage

Introduction to Fitness-For-Service Assessment Using

API/ASME Standard API 579-1 / ASME FFS-1
 Questions?

The Lloyd’s Register Group

For more information, please contact: works to enhance safety and
approve assets and systems at
Lloyd’s Register Capstone, Inc. sea, on land and in the air –
1505 Hwy 6 South, Suite 100 because life matters.
Houston Texas 77077
T (1) 281 493 2236
F (1) 281 493 5156