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Seminars

Fitness for Service: Pressure Vessels, Tanks and Piping Systems



Introduction:


A plant objective is to attain the maximum economic benefit and service life from existing equipment without sacrificing integrity. This requires accurate assessment of the condition of the equipment and their suitability for the actual service. Fitness-For-Service (FFS) assessments are quantitative engineering evaluations that are performed to demonstrate the structural integrity of an in-service pressure equipment/component containing a flaw or damage. In June 2007 API and ASME produced a joint update of each society’s version of FITNESS FOR SERVICE.  The new standard is now called API 579-1/ASME FFS-1 2007 Fitness-For-Service. It has become the defect international standard for conducting FFS assessments. The main deliverables from FFS assessments are improved plant integrity and reduced maintenance costs.

 

The participant in this integrated and comprehensive course will learn to apply the rules of the API/ASME 579 standard "Fitness-for-Service" to evaluate the integrity and remaining life of pressure vessels, storage tanks, piping systems and pipelines, to make cost effective run-repair-replace decisions, and select the appropriate repair options. In this program you will learn:

 

  • Fundamental principles of fitness-for-service, their practical application through case histories, and a step-by-step evaluation process for each type of degradation mechanism
  • Basic design of pressure vessels, piping and storage tanks, fundamental principles of component integrity, application of the ASME code rules, material properties of strength and toughness, and the introduction to stress and fracture mechanics
  • A review of degradation mechanisms and the application of API/ASME 579 to brittle fracture, general metal loss, local wall thinning, pitting, blisters and laminations, mechanical defects (dents, gouges, misalignment, and distortion), crack-like flaws (stress corrosion cracking, weld flaws, crack-like defects), fatigue, HIC & SOHIC and fire damage

Course Objectives:


By the end of this course, delegates will be able to:

 

  • Latest techniques to determine the fitness-for-service of operating tanks, vessels, piping systems and pipelines; and make cost-effective run-repair-replace decisions based on the principles of API recommended practice 579 "Fitness-for-Service"
  • Balanced approach between the fundamental technical principles of structural integrity, stress and fracture analysis, and their practical application to field conditions
  • Provides the participants with the tools necessary to recognize and assess defects in pressure vessels, storage tanks and piping
  • Presents and applies the fundamentals rules of the ASME code to operating equipment and systems
  • Introduces the participants to the practical application of the ASME and API rules for structural integrity of static equipment and pipelines, and their use to assess remaining life
  • Applies API/ASME 579 "Fitness-for-Service" through practical examples to analyze degraded conditions and make cost-effective repair or use-as-is decisions
  • Applies the step-by-step 3-level approach of API/ASME 579 to evaluate inspection results and recognize potential failure modes
  • Technical basis for reliability-based (risk-based) evaluation of remaining life
  • Latest developments in defect assessment techniques, starting with simple rules (level 1) and progressing to the more comprehensive evaluation techniques (level 3)
  • Participants will be able to evaluate the structural integrity of corroded or damaged equipment, and assess their remaining life. Degradation mechanisms include: brittle fracture, general metal loss, local wall thinning, pitting, blisters and laminations, mechanical defects (dents, gouges, misalignment, and distortion), crack-like flaws (stress corrosion cracking, weld flaws, crack-like defects), fatigue, and fire damage

Who Should Attend?


Welders I & II, Fabricators, Welding Metallurgy Technicians, Welding Supervisors, Welding Sales/Service Technicians, Foreman Mechanical Maintenance, Engineering Technicians, Pipefitters, Weld Inspectors, Production Welders, Managers, Petroleum Engineers, Senior Welders and Operators, Production and Maintenance Staff, Inspectors, anyone who works with welding, Inspection Engineers, Mechanical Engineers, Electrical Engineers, NDT Personnel, Quality Assurance Personnel, Auditors, Testing Laboratory Personnel, and Maintenance Personnel, Qualifying Welders, Brazers and Operators, technical professionals, supervisors and managers responsible for ensuring the integrity and cost-effective operation of in-service pressure equipment, storage tanks, piping and pipelines throughout their life cycle including design, operation, and maintenance in the petroleum, petrochemical, process and power industries, Plant engineers and designers, corrosion and materials engineers, project engineers, Reliability and integrity supervisors and engineers including safeguarding/MOC engineers, Inspection engineers and inspectors responsible for monitoring and assessing the condition of pressure equipment and piping systems, Maintenance and operations supervisors and engineers responsible for shutdown planning and implementation, maintenance and repairs/alterations of pressure vessels, heat exchangers, storage tanks, piping and pipelines

Course Outline:


Foundations of Fitness-For-Service Assessment

  • Overview of API codes and standards
  • Overview of ASME codes and standards with historical background
  • Overview of Mechanical Integrity of Pressure Vessels & Piping System

 

Fitness For Service

  • Overview of API 579 contents, objectives and applications
  • How to apply API 579 for cost-effective run-or-repair decisions
  • Fitness-for-Service assessment procedure
  • An overview of what is new in the latest release

 

Structure and Contents of the FFS Standard

  • List of Parts and Annexes and examples of major Parts
  • PART 1 - Introduction
  • PART 2 - Fitness-For-Service Engineering Assessment Procedure

 

Thickness, MAWP & Stress Equations for a FFS Assessment

  • Calculation of TMIN, MAWP (MFH) & Membrane Stress
  • Pressure Vessel & Boiler Components: Shells, Heads, Nozzles
  • Piping components & Boiler Tubes
  • Storage Tanks

 

Damage Mechanisms

  • Deterioration and Failure Modes
  • Pre-Service and In-Service Deficiencies

 

NDE (NDT) Techniques

  • PT, VT, MT, ET, UT, RT

 

Assessment of Existing Equipment for Brittle Fracture

  • Overview of Brittle Fracture Mechanism
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of General Metal Loss

  • Overview of Corrosion Mechanisms
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of Local Metal Loss

  • Overview of Local Metal Loss Mechanisms
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of Pitting Corrosion

  • Overview of Pitting Corrosion Mechanisms
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Hydrogen Blisters, HIC & SOHIC

  • Overview of Hydrogen Damage
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Weld Misalignment & Shell Distortions

  • Overview of Weld Misalignment & Shell Distortions
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of Crack-Like Flaws

  • Overview of Fracture Mechanics
  • Elements of RSTRENG
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation  

 

Assessment of Components Operating in the Creep Range

  • Overview of Creep Damage Mechanisms
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of Fire Damage

  • Overview of Fire Damage
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of Dents, Gouges, and Dent-Gouge Combinations

  • Overview of Mechanical Damage
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

 

Assessment of Laminations

  • Overview of Laminations and their Role
  • Data Requirements
  • Assessment Techniques and Acceptance Criteria (Levels 1-3)
  • Remaining Life Assessment and Remediation

COURSE LOCATIONS

Code From To City Fee
WT26 09 Feb 2020 13 Feb 2020 Alexandria US$ 3900 Book
WT26 06 Apr 2020 10 Apr 2020 Kuala Lumpur US$ 4500 Book
WT26 22 Jun 2020 26 Jun 2020 Istanbul US$ 4500 Book
WT26 24 Aug 2020 28 Aug 2020 London US$ 5000 Book
WT26 26 Oct 2020 30 Oct 2020 Bali US$ 5500 Book
WT26 28 Dec 2020 01 Jan 2021 Madrid US$ 5500 Book


DUBAI OFFICE

Ittihad Deira Building,
Al Ittihad Rd, Deira
Dubai,
UAE

info@petrogas-training.com

USA OFFICE

642 E14 Street,
10009-13 Manhattan,
New York (NY)
USA

info@petrogas-training.com

EGYPT OFFICE

52 General Kamal Hejab Street,
Suez Bridge,
Cairo,
Egypt

info@petrogas-training.com
 

COURSE CERTIFICATE

Certificate of Completion will be provided to the candidate(s) who successfully attend and complete the course. Training hours attendance percentage of 75% is required.


TRAINING HOURS

Standard course hours: 8:30 A.M. to 3:30 P.M. Informal discussions: 4:30 P.M. to 5:30 P.M.


TRAINING METHODOLOGY

We use a blend of interactive and hands-on methods, active participation, a variety of instructional techniques, dynamic presentations, individual and group exercises, in depth discussion, DVD’s, role-plays, case studies, examples. All of the information, competencies, knowledge and skills acquired within our training programs, are 100% transferrable to the participants’ workplace.


ASSESSMENT & EVALUATION

Pre-Test and Post-Test Assessment are applied on 5-day and 10-day programs. Also, post course evaluation and candidate’s evaluation are applied to add another level of quality measurement. Candidates’ feedback is highly appreciated to elevate the training service quality.


ORGANIZATIONAL IMPACT

A- Have staff trained in the latest training and development approaches

B- Support nationalization and talent management initiatives

C- Have properly trained and informed people who will be able to add value

D- Gain relevant technical knowledge, skills and competencies


PERSONAL IMPACT

A- Develop job related skills

B- Develop personal skills in subject matter

C- Have a record of your growth and learning results

D- Bring proof of your progress back to your organization

F- Become competent, effective and productive

G- Be more able to make sound decisions

H- Be more effective in day to day work by mastering job-related processes

I- Create and develop competency to perform job well


FREQUENT NOMINATIONS SCHEME

A- 10% discount after 05 candidates’ registration.

B- 15% discount after 10 candidates’ registration.    

C- 20% discount after 20 candidates’ registration.

D- 25% discount after 25 candidates’ registration.

E- 30% discount after 30 candidates’ registration

F- Higher discount rates will be offered based on work volume with different clients.  


SEVERAL NOMINATIONS ON THE SAME COURSE SCHEME

A- One extra free seat is offered on 4 candidates on the same course and dates.

B- Two extra free seats are offered on 6 candidates on the same course and dates.

C- Three extra free seats are offered on 8 candidates on the same course and dates.

D- Four extra free seats are offered on 10 candidates on the same course and dates.

E- Five extra free seats are offered on 12 candidates on the same course and dates.


REGISTRATION POLICY

Nominations to our public courses are to be processed by the client’s Training and/or HR departments. A refund will be issued back to the client in the event of course cancellation or seat unavailability. A confirmation will be issued to the relevant department official(s). 


CANCELLATION POLICY

If a confirmed registration is cancelled less than 5 working days prior to the course start date, a substitute participant may be nominated to attend the same course or a 20% cancellation charge is applied. In case of a no-show, a 100% fee will be charged.


PAYMENT POLICY

Payment is due upon receiving the course confirmation, invoice and/or proforma invoice. However; the fee due can be wire transferred to our bank account directly after course completion. Our bank details are illustrated on the confirmation, invoice and proforma invoice, as well. The above documents can be communicated electronically, i.e., in a soft copy or/and in hard copy based on customer’s request.


COPYRIGHT

© 2017. Material published by PETROGAS shown here is copyrighted. © 2017. All rights reserved. Any unauthorized copying, distribution, use, dissemination, downloading, storing in any medium, transmission, reproduction or reliance in whole or any part of this course outline is prohibited and will constitute an infringement of copyright.