Application of API579-1 / ASME FFS in

carrying out Fitness For Service assessments

of damaged pressure equipment

HERA Pressure
CoverEquipment
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Workshop 2016
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Application of API579-1 for FFS Assessments
Background

I ITL for about 5 years

have worked at

overseen over 50 assessments in the past 3 years

for 15 clients and saved $manymillions

WHY,
WHAT,
WHEN and
HOW Cover page title
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Application of API579-1 for FFS Assessments
WHY?

If a piece of pressure equipment no longer meets the design it can be

evaluated to ensure safe continued operation.
An FFS assessment will enable asset owner to make informed decision
whether to

Run as is
Repair
Rerate
Replace Cover page title
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Application of API579-1 for FFS Assessments
WHAT?

Components primarily pressure equipment

Typically:
Pressure Vesselshells, heads, nozzles
Cooler Header box plates
Heat Exchanger tubes
Pipelines and piping
Also: the principles can be applied to structural and other
mechanical components
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Application of API579-1 for FFS Assessments
WHEN?

When a component no longer meets the basis of it’s design.

Due to defects associated with in-service operation:
Generalised or localised metal loss
Pitting corrosion Cracks
Laminations Hydrogen Damage
Dents and gouges
Due to changes to design conditions:
Creep
Brittle failure
Fire damage
Due to defects associated with manufacture:
Weld misalignments Cover page title
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Application of API579-1 for FFS Assessments
HOW?

AS/NZS 3788 – Pressure Equipment -In Service Inspection

has some basic assessments

calc complexity
Level 1
API 579-1/ASME FFS

conservatism
Covers a wide range of defects
Formalises methodology of assessment
Level 2
Consistent repeatable results
Level 3
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Application of API579-1 for FFS Assessments
Example 1 Local Metal Loss

• Corrosion was found of a

nozzle of a vessel.
• Measurements taken and
3D CAD model created
• Level 3 (FEA) assessment
demonstrated fit for service
with a FCA of 2mm

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Application of API579-1 for FFS Assessments
Example 1 Concepts

• API579-1 Required data

Rubbish in rubbish out. API often defines
what measurements are recommended.
• Typically corrosion but also
grinding
Surface defects may be removed by
grinding – leaving a local thin area
• Level 3 typically requires FE
Analysis
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Application of API579-1 for FFS Assessments
Example 2 General Metal Loss

• Corrosion was found under

insulation of a nozzle of a
vessel.
• 3D laser scan and UT
• Level 2 assessment
demonstrated fit for service
with a FCA of 2mm

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Application of API579-1 for FFS Assessments
Example 2 Concepts

• Know the cause of defect

In order to Eliminate, minimise or
control the mechanism
• FCA – Future Corrosion
Allowance
• Remaining Life
The FFS assessment applies to the
component as found possible plus FCA

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Application of API579-1 for FFS Assessments
Example 3 Pitting Corrosion

• Pitting corrosion found on

bath heater tube during
routine inspection.
• Photos and pit depth
readings taken
• Level 2 assessment found fit
for service but with 1 year
remaining life
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Application of API579-1 for FFS Assessments
Example 3 Concepts

• RSF
Remaining Strength Factor typically
allowable is 0.9

• Level of assessment
API sets out criteria for each level of
assessment

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Application of API579-1 for FFS Assessments
Example 4 Cracks

• Defects observed during

phased array UT inspection
of heat exchanger nozzle
• Calculated crack parameters
• FE Analysis predicted
stresses
• Level 3 assessment
demonstrated crack was
safe Cover page title
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 Application of API579-1 for FFS Assessments
Example 4 Concepts
1.2 FAD (Failure Assessment Diagram )
1
• Non-growing crack
Fail
(Know what caused the defect). A crack
0.8
which is suspected to be growing will be
Kr0.6 Pass assessed differently.

0.4 • FAD Failure Assessment

0.2
Diagram
A crack like flaw can be characterised on FAD
0
0 0.2 0.4
Lr
0.6 0.8 1
• Leak before rupture
Similar to predicting a remaining life
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Application of API579-1 for FFS Assessments
Example 5 - Dent

• Pigging found a dent in a

pipeline
• Site measurements and UT
• Level 3 FE Analysis
demonstrated that the
pipeline was still safe for a
restricted number of cycles

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Application of API579-1 for FFS Assessments
Example 5 – Concepts

• Replicate the dent

process
Different cases require defend
types of FE analysis

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Application of API579-1 for FFS Assessments
Example 6 – Creep

• An anomaly was seen in a

spun cast Incoloy tee
operating at 790°C
• Worst case assumed to be a
crack
• Level 3 assessment FEA and
calculations demonstrated a
remaining life of more than 6
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Application of API579-1 for FFS Assessments
Example 6 – Concepts

• Often assumptions are

required.
These assumptions will tend to be
conservative or 2 extreme cases.
• Less common material
properties addressed in API579
Methodologies for calculating creep or
facture toughness properties.
• Other useful tools.
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Application of API579-1 for FFS Assessments
Example 7 – Brittle failure

• A risk of exceeding the

minimum design
temperature highlighted
from Safety case
• Level 2 assessment relating
stress to temperature
showed vessel to be fit for
service provided start up is
managed Cover page title
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 Application of API579-1 for FFS Assessments
Example 7 – Concepts

40
• The less conservative
20
and more detailed
0 assessments often need
more controls
3 2.5 2 1.5 1 0.5 0
-20
MAT of Head

MAT (C)
NH3 cooling -40 More frequent inspections
-60 In service monitoring
-80 Leak detection
-100

-120
Internal Pressure (MPa)

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Application of API579-1 for FFS Assessments
Example 8 – Laminations

• A detailed inspection of a
vessel for rerate showed areas
of layers of defects.
• A level 2 assessment
combining a Part 9 (cracks)
and Part 13 (Laminations)
assessment showed that the
vessel was fit for service at it’s
rerated conditions.
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Application of API579-1 for FFS Assessments
Example 8 – Concepts

• May need to consider

combinations of defects
Examples:
Lamination and crack like flaw
Dents and local metal loss
General metal loss and pitting
Creep and crack like flaw

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