COURSE OVERVIEW:

Fitness-for-Service (FFS) assessments represent a sophisticated engineering methodology used to determine the structural integrity of in-service pressurized equipment that contains identified flaws or damage. By applying the quantitative technical procedures outlined in the API 579 standard, engineers can make informed decisions regarding the continued operation, repair, or replacement of aging assets. This approach allows for a scientific determination of safety margins, moving beyond the simple "go/no-go" criteria often found in original construction codes.

The scope of this training program covers the multidisciplinary nature of FFS, integrating material properties, stress analysis, and non-destructive examination data. It addresses a wide variety of equipment types, including process piping, pressure vessels, and atmospheric storage tanks, across different industry sectors. Participants will learn to navigate the three levels of assessment, ranging from conservative screening methods to complex numerical modeling, ensuring that the level of analysis is proportional to the risk and severity of the observed damage.

Coverage includes detailed evaluation procedures for common degradation mechanisms such as localized metal loss, pitting, blisters, and crack-like flaws. The course also explores specialized assessments for equipment exposed to fire damage, creep, and mechanical distortions like dents or gouges. By the end of this curriculum, attendees will understand how to calculate the remaining strength and life of a component, providing a solid technical basis for extending inspection intervals and optimizing maintenance budgets without compromising personnel safety or environmental protection.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the fundamental philosophy and organization of the API 579-1/ASME FFS-1 standard.
2. Differentiate between Level 1, Level 2, and Level 3 assessment requirements and applications.
3. Calculate the Remaining Strength Factor (RSF) for components with localized thinning.
4. Evaluate the impact of pitting corrosion on the pressure-containing capability of vessels.
5. Assess the structural significance of laminations and weld misalignments in piping.
6. Perform engineering evaluations for crack-like flaws using fracture mechanics principles.
7. Determine the suitability of equipment for continued operation after fire exposure.
8. Analyze the effects of mechanical damage, including dents and gouges, on integrity.
9. Assess the remaining life of components operating in the creep temperature range.
10. Evaluate the risk of brittle fracture for equipment operating at low temperatures.
11. Define the necessary data requirements for a comprehensive fitness-for-service study.
12. Establish appropriate monitoring programs for flaws that are left in-service.
13. Integrate FFS results into an overall mechanical integrity and risk management program.

TARGET AUDIENCE:

This course is intended for mechanical engineers, integrity specialists, plant inspectors, and reliability professionals who are responsible for making run-repair-replace decisions for aging industrial equipment.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.