COURSE OVERVIEW:

Fitness-for-Service (FFS) assessments are quantitative engineering evaluations performed to demonstrate the structural integrity of an in-service component containing a flaw or damage. This course provides an intensive exploration of the API 579-1/ASME FFS-1 standard, which is the global benchmark for evaluating pressurized equipment such as vessels, piping, and tanks. Participants will learn how to apply multi-level assessment techniques to determine if damaged equipment can continue to operate safely or if repair or replacement is mandatory.

The scope of this training involves a detailed analysis of various damage states, including metal loss (corrosion/erosion), pitting, cracks, blisters, and mechanical distortion (dents/bulges). We will examine the three-tier assessment approach, moving from conservative Level 1 screening to sophisticated Level 3 finite element analysis (FEA). Attendees will gain the technical skills required to calculate the "Remaining Strength Factor" (RSF) and determine the "Reduced Maximum Allowable Working Pressure" (MAWPr) for compromised assets.

Furthermore, the course addresses the critical integration of material properties, stress analysis, and inspection data. Attendees will learn how to handle uncertainties in flaw sizing and material toughness, ensuring that safety margins are maintained without the need for unnecessary and costly shutdowns. By mastering the FFS methodology, engineers can make informed, data-driven decisions that optimize the balance between plant safety, operational availability, and maintenance expenditures.

COURSE OBJECTIVES:

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

1. Explain the fundamental philosophy and scope of the API 579/ASME FFS-1 standard.
2. Navigate the multi-level assessment structure (Levels 1, 2, and 3).
3. Perform Level 1 and Level 2 assessments for general and localized metal loss.
4. Evaluate the impact of pitting corrosion on pressure-retaining components.
5. Analyze the structural integrity of equipment containing cracks using fracture mechanics.
6. Assess the severity of blisters and HIC (Hydrogen Induced Cracking) damage.
7. Evaluate geometric imperfections such as dents, bulges, and out-of-roundness.
8. Calculate the Remaining Strength Factor (RSF) and its significance.
9. Determine the Remaining Useful Life (RUL) of damaged equipment.
10. Establish appropriate inspection intervals based on FFS results.
11. Utilize FFS techniques to justify continued operation at reduced pressure.
12. Integrate NDE results and material property data into FFS calculations.
13. Prepare a comprehensive FFS assessment report for regulatory compliance.

TARGET AUDIENCE:

Mechanical Engineers, Pressure Vessel Engineers, Asset Integrity Personnel, Reliability Engineers, and Senior Inspection Professionals.

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.