COURSE OVERVIEW:

The meaning of Pipework Fitness-for-Service (FFS) involves the rigorous engineering evaluation of piping systems that have sustained damage or degradation to determine if they remain safe for continued operation. This course focuses specifically on the application of the API 579-1/ASME FFS-1 standard to process piping designed under ASME B31.3. Unlike general pressure vessel FFS, pipework evaluation must account for the high complexity of piping geometries, including elbows, branch connections, and the significant impact of external loads such as thermal expansion, vibration, and weight.

The scope of the training covers the most common degradation mechanisms found in refinery and chemical plant piping, including localized metal loss, pitting, and environmental cracking. Participants will learn how to execute Level 1 and Level 2 assessments, which provide rapid, yet technically sound, screening tools for inspectors and engineers. The course emphasizes the calculation of the Remaining Strength Factor (RSF) and the determination of the Maximum Allowable Working Pressure (MAWP) for the degraded state, ensuring that the piping system maintains an acceptable margin of safety against failure.

The coverage of this program includes ten modules that move from the basics of piping stress analysis to the advanced evaluation of crack-like flaws and vibration-induced fatigue. Key topics include the assessment of "dead legs" and "small bore" piping, the evaluation of piping distortions and misalignments, and the management of "Corrosion Under Insulation" (CUI) through FFS. The course also addresses the practicalities of field data collection, teaching participants how to obtain accurate thickness profiles and flaw dimensions required for a high-confidence FFS assessment.

COURSE OBJECTIVES:

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

• Distinguish between the design requirements of ASME B31.3 and the evaluation rules of API 579.
• Perform Level 1 and Level 2 assessments for piping metal loss.
• Calculate the Remaining Strength Factor (RSF) for complex piping geometries.
• Evaluate the impact of external piping loads on the FFS outcome.
• Assess the severity of pitting clusters in high-pressure process lines.
• Utilize the Failure Assessment Diagram (FAD) for evaluating piping cracks.
• Determine the remaining life of piping subjected to erosion and corrosion.
• Analyze the risk of brittle fracture for piping in low-temperature service.
• Assess the integrity of piping components with geometric distortions.
• Formulate "Run-Repair-Replace" decisions based on FFS results.
• Integrate FFS results into the plant's Risk-Based Inspection (RBI) program.
• Document FFS evaluations to meet the requirements of API 570.

TARGET AUDIENCE:

This course is designed for Piping Engineers, Plant Inspectors, Mechanical Engineers, Reliability Specialists, and Maintenance Managers in the oil, gas, and petrochemical sectors.

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.