COURSE OVERVIEW:

Fitness-for-Service (FFS) assessments are quantitative engineering evaluations performed to demonstrate the structural integrity of an in-service component that may contain a flaw or damage. This course provides a comprehensive and practical exploration of the API 579-1/ASME FFS-1 standard, which is the global benchmark for evaluating the safety and reliability of pressurized equipment. Participants will learn how to make "run-repair-replace" decisions based on rigorous engineering analysis rather than conservative code-compliance alone.

The scope of this workshop covers the multi-level assessment approach, ranging from simple designer-level screenings to advanced stress analysis. We will examine a wide variety of damage mechanisms, including general and localized metal loss, pitting, blisters, laminations, and various forms of cracking. The curriculum is designed to provide attendees with a deep understanding of how to collect the necessary inspection data, select the correct assessment level, and calculate the Remaining Strength Factor (RSF) for degraded assets.

Coverage includes the practical application of assessment procedures for brittle fracture, creep damage, and fire damage. Attendees will participate in hands-on calculation exercises that simulate real-world refinery and petrochemical scenarios. By the end of this workshop, participants will be equipped with the technical expertise to perform FFS assessments that optimize maintenance costs, minimize unnecessary shutdowns, and ensure the continued safe operation of critical plant infrastructure.

COURSE OBJECTIVES:

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

• Explain the fundamental philosophy and organization of the API 579-1/ASME FFS-1 standard.
• Distinguish between Level 1, Level 2, and Level 3 assessment requirements and competencies.
• Determine the Remaining Strength Factor (RSF) and its impact on the Maximum Allowable Working Pressure.
• Perform detailed assessments for general and localized metal loss using thickness data.
• Evaluate the structural integrity of pressure vessels containing pits and pitting clusters.
• Analyze the severity of shell distortions, out-of-roundness, and weld misalignments.
• Assess the risk of brittle fracture and establish Minimum Design Metal Temperatures (MDMT).
• Evaluate the impact of hydrogen blisters and laminations on vessel pressure boundaries.
• Conduct crack-like flaw assessments using fracture mechanics principles.
• Estimate the remaining life of components operating in the creep and high-temperature range.
• Analyze equipment for potential re-rating or life extension following fire damage.
• Documentation of FFS findings in a format suitable for regulatory and insurance audits.

TARGET AUDIENCE:

This workshop is essential for Integrity Engineers, Pressure Vessel Engineers, Plant Inspectors, Stress Analysts, Maintenance Engineers, and Reliability Professionals responsible for the mechanical integrity of process equipment.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize 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.