LLOYDS REGISTER CAPSTONE

Introduction to Fitness-For-Service (FFS) Assessment Using API/ASME Standard API 579-1 /

ASME FFS-1

Webinar SeriesApril 22, 2010

Introduction to Fitness-For-Service Assessment Using API/ASME Standard API 579-1 / ASME FFS-1

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

Overview

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 inininin----serviceserviceserviceserviceequipment 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

Asset lacks original design information or it may have exceeded its useful life

When is FFS Assessment needed?

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

Guidelines to make run-repair-replace decisions of in-service equipment are required

What happens to in-service equipment?

Time dependent degradation Upset operating condition (Pressure, Temperature) Fluid - Material Interaction

Inspection (original fabrication and in-service flaws) Maintenance (including repairs and replacement)

What need to be done?

Scope of FFS Assessments

Introduction to Fitness-For-Service Assessment Using API/ASME Standard API 579-1 / ASME FFS-1

Scope of FFS Assessments

Brittle fracture Fire damage Metal loss due to corrosion /

erosion (general, local, and pitting) HIC damage (blisters, HIC, SOHIC) Geometrical irregularities (weld

misalignment and distortion) Crack-like flaws Creep Dent and gouges Laminations

i Amine crackingi Ammonia crackingi Carbonate crackingi Hydrogen damage (H2S, HF)i Hydrogen attacki Caustic cracking in SSi Chloride cracking in SSi Polythionic cracking in SS

Failure conditions and types of flaws

Introduction to Fitness-For-Service Assessment Using API/ASME Standard API 579-1 / ASME FFS-1

Scope of Assessments

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

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

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 Fracture

Fire Damage

Corrosion/Erosion

Crack-like Flaw

Creep Damage

Mechanical Damage

Part 3 Part 9

Part 11 Part 4 Part 5 Part 8 Part 9 Part 10

Part 4 Part 5 Part 6 Part 7

Part 9 Part 5 Part 8 Part 9 Part 12 Part 13

Part 10 Part 9

Introduction to Fitness-For-Service Assessment Using API/ASME Standard API 579-1 / ASME FFS-1

Evaluation Techniques and Derivable

Conservative screening

Minimum amount of inspection or component information

Plant inspection or engineering personnel

More detailed less conservative with more accurate results

Inspection information

Qualified engineering personnel

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

Level 1

Level 2

Level 3

Assessment Levels

Introduction to Fitness-For-Service Assessment Using API/ASME Standard API 579-1 / ASME FFS-1

Evaluation Techniques and Derivable

4 Step 1 Flaw/Condition Identification (Mode of Failure) 4 Step 2 - Applicability and Limitations4 Step 3 - Data Requirements4 Step 4 - Assessment Techniques and Acceptance Criteria4 Step 5 - Remaining Life Evaluation4 Step 6 - Remediation4 Step 7 - In-Service Monitoring4 Step 8 - Documentation

General Assessment Procedure / Steps

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

Lloyds Register Capstone FFS Assessment

SimulationsMaterial Testing

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

The Lloyds Register Group works to enhance safety and approve assets and systems at sea, on land and in the air because life matters.

For more information, please contact:

Lloyds Register Capstone, Inc.1505 Hwy 6 South, Suite 100Houston Texas 77077T (1) 281 493 2236F (1) 281 493 5156

Questions?