Fitness-For-Service Overview

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Contents
Why fitness-for-service Definition of fitness-for-service Common standards of assessment BS 7910 and API RP 579

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Why fitness-for-service
Commissioning Forced shutdown frequency End of life
Risk based inspection, Condition monitoring

Classic bath tub curve

Life extension, Fitness-for-service, Modification, Refurbishment, Repair

Design life

Time
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Why fitness-for-service
Used for equipment management Optimisation and life extension of assets Improve safety Improve availability of equipment Applicable to all stages of equipment life, for example:
fabrication flaws inin-service inspection Life extension
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Definition of FFS
A multi-disciplinary engineering analysis of equipment for continued operation Flaw Information

Material Information

Stress Information Sometimes referred to as the structural integrity triangle

FFS Assessment

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FFS standards
Regulatory bodies usually require that assessments are conducted to recognised and generally accepted good engineering practice This has lead to the formulation of international standards and procedures

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Common FFS Standards

BS7910:1999

Incorporating amendment No.1

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Common FFS standards

ANSI/API RP 579:2000

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Common FFS standards

ASME B31.G

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Common FFS standards

SINTAP

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Common FFS standards

R6 procedure

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Common FFS standards

R5 procedure

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Common FFS standards

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Common FFS standards

TWI worldwide industry survey into risked based life management practices and their relationship to FFS.

To what are FFS assessments being conducted

24%

API 579 (50%) BS 7910 (50%)

17% Published procedures Unknown or mixture

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59%

In-house procedures

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Common FFS standards

Top two reasons for undertaking a FFS: Determining remaining life of damaged plant Assessment to ensure safe operation beyond design life Top two equipment types assessed: General pressure vessels Process piping

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Scope of API 579

Prepared by API primarily for equipment designed to ASME & API codes (Section I/VIII, B31.1/3, API 650 & 620)

Covers wide range of flaw/damage types found in refinery/petrochemical equipment Procedures and supporting data relate to ASME design specifications and materials
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Organisation of API 579

Modular, based around flaw and damage type: Brittle fracture General or local metal loss, and pitting Blisters and laminations Weld misalignment, dents, distortions CrackCrack-like flaws Fire damage

Extensive annexes containing materials data, formulae, and reference solutions

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Levels of assessment
API 579 has three levels, relating to competence of assessors, extent of data gathering, conservatism of analysis method: Level 1 is aimed at inspectors for use onon-site for quick decisions with minimum data Levels 2 is intended for qualified engineers Level 3 is an advanced assessment requiring detailed data and analysis and expert staff BS 7910: requires qualified engineers
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Scope of BS 7910
Prepared by British Standards for all types of metallic structures Originated from BS PD 6493 for defects in fusion welded structures Emphasis on fatigue and fracture assessment of flaws in welded components, and also covers creep cracking and locally thinned areas Annexes give extra guidance and data
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Summary
FFS is widespread and as manufacturing plants continued to age, its usage will grow There are many assessment standards; API 579 and BS 7910 are most common in the nonnonnuclear industry API 579 is designed for ASME code equipment and can be used by plant inspectors onon-site API 579 has strengths in corrosion and non crackcrack-like assessment for pressure equipment BS 7910 is for all welded structures and has strengths in fracture and fatigue assessment
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