FITNESS for SERVICE ENGINEERING ASSESSMENT & PLANT INTEGRITY
MANAGEMENT
FOUR DAYS PUBLIC TRAINING
GRAN MAHAKAM, – HOTEL, BLOK M, JAKARTA,
22 – 25 July 2008
WHAT IS Fitness For Service?
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Burned pressure vessels; deformed pipes; corroded storage tank;
cracked flanges. Should we replace these equipments? Is it still
operable? If so, then is it still operable within required
conditions? Is it really safe to operate? Question no more, FFS
Assessment can answer it.
An FFS assessment is an engineering analysis of equipment to
determine whether it is fit for continued service. The equipment may
contain flaws/damaged areas, may not comply with current design
standards, or maybe subject to more severe operating conditions than
the design conditions.
The result of an FFS assessment is a decision to alter, repair,
monitor, or replace the equipment. FFS assessment may also provide
guidance on appropriate inspection intervals or remaining life
estimation depends on flaw type and severity.
FFS assessments employ analytical methods to assess flaws/damage and
require an interdisciplinary approach with an understanding of:
• Damage mechanisms and material behavior.
• Past and future operating conditions.
• NDT examination techniques (flaw location and sizing).
• Material properties (environmental effects).
• Stress analysis (finite element analysis, FEA)
• Data analysis (engineering reliability models).
The use of FFS assessment can extend the useful life of aging
equipment. In some cases, it allows new equipment with acceptable
flaws/damage to enter service, resulting in the avoidance of repair
or replacement in situations in which the conventional codes would
have required massive efforts. Thus greatly reducing costs and time
required for equipments replacement/repair.
API RP 579 GUIDELINES
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API RP 579 provides guidance for conducting FFS Assessment using
methods specifically prepared for equipment in the refining and
petrochemical industry. The guidelines can be used to make run-
repair-replace decisions to ensure that pressurized equipment
containing flaws can continue to operate safely.
API RP 579 supplements the requirements in API 510 (pressure vessel
inspection code), API 570 (piping inspection code), and API 653
(aboveground storage tank inspection code). API RP 579 basically has
three functions:
• To ensure safety of plant personnel and the public while older
equipment continues to operate.
• To provide technically sound FFS assessment procedures to ensure
that different service provider furnish consistent life
predictions.
• To help optimize maintenance and operation of existing facilities
to maintain availability of older plants and enhance long-term
economic viability.
Assessment procedures in API RP 579 can be used for FFS assessments
and for rerating of components designed and constructed to the
following codes:
• ASME B&PV code section VIII, Division 1 & Division 2;
• ASME B&PV code section I;
• ASME B31.3 & ASME B31.1 Piping code;
• API 650 & API 620
• Other recognized codes & standards
API RP 579 provides 9 types of individual flaws/damages assessment.
Each flaw type can be used in conjunction with other type of flaw to
assess a multiple flaw occurrence. For example, an out-dated burned
pressure vessel can be assessed with fire damage flaw, general metal
loss, localized metal loss, blisters & laminations flaw, and shell
distortion flaw.
API RP 579 provides three level of assessment for each for each flaw
and damage type. Each assessment level provides a balance of
conservatism, the amount of information required for the assessment,
and the complexity of analysis.
COURSE OUTLINE
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• Background & Introduction
• FFS Engineering Assessment Procedures
• Discussion of damage mechanisms and the importance of damage
identifications.
• Brittle Fracture
• Provides assessment procedures for evaluating the resistance to
brittle fracture of existing carbon and low alloy steel pressure
vessels, piping, storage tanks.
• Provides criteria to evaluate normal operating, start-up, upset,
and shut-down conditions.
• General Metal Loss
• Provides assessment procedures to evaluate general corrosion.
• Allows either point thickness readings or detailed thickness
profiles for thickness data.
• Local Metal Loss
• Provides assessment techniques to evaluate single and networks of
local thin areas and groove-like flaws in pressurized components.
• Requires detailed thickness profiles for the assessment.
• Methodology to evaluate blisters.
• Pitting Corrosion
• Provides assessment procedures to evaluate widely scattered
pitting, localized pitting, pitting which occurs within a region
of local metal loss, and a region of localized metal loss located
within a region of widely scattered pitting.
• Can evaluate a network of closely spaced blisters.
• Blisters & Laminations
• Provides assessment procedures to evaluate isolated and networks
of blisters & laminations.
• Includes provisions for blisters located at weld joints and
structural discontinuities such as shell transitions, stiffening
rings, and nozzles.
• Weld Misalignments and Shell Distortion
• Provides assessment procedures to evaluate stresses resulting
from geometric discontinuities in shell type structures
including weld misalignment and shell distortions (for example,
out-of-roundness, bulges, and dents).
• Crack-like Flaws
• Provides assessment procedures to evaluate crack-like-flaws.
• Covers recommendations for evaluating crack growth, including
environmental concerns.
• Fire Damage
• Provides assessment procedures to evaluate equipment subject to
fire damage
• Provides a methodology to rank and screen components for
evaluation based on the heat exposure experienced during fire.
• Refers to assessment procedures in the other sections of this
publication to evaluate component damage.
• Practical Example Problems Discussion.
Course will be presented up to level 2 assessments, which is
sufficient for general FFS Assessment.
WHO SHOULD ATTEND
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Plant engineers in mechanical reliability programs, plant
inspectors, central engineering staff, and consultants for refining
and petrochemicals. Training in API RP 579 can also be beneficial
for the pulp, paper, fossil fuel utility, and other industries that
use and maintain pressurized equipment.
DATES & PLACE
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Dates : 22 - 25 July 2008
Place : Gran MAHAKAM-Hotel-Jakarta
Jl. Mahakam I No.6, Blok M
Jakarta 12310
For Resevation; reservation@granmahakam.com
Phone: +62 21 720 9966
Fax : + 62 21 725 2011
INFORMATION & REGRISTRATION
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HANDAL CONSULTING & TRAINING
Jl. Danau Semayang Blok B III No.104, Pejompongan, Jakarta
Website: 1. http://www.handalconsulting.com 2.
http://www.handal.co.id
e-mail: handalcentre@gmail.com
Phone: 021 – 5708775
Fax : 021 – 5702113
Contac Persons: Ms. Yayuk, Ms. Dina
24 hours information services; 021-70897550, 081511831936
COURSE FEES
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Course fee is Rp. 5.650.000,- / delegate including; training
modules, training KIT, merchandise & certificate also; 2 x Coffee
Break + Snacks, Lunch, and exluding accomudation and tax.
METHOD OF PAYMENT
COULD BE TRANSFERRED TO THE FOLLOWING ACCOUNT;
HANDAL WIRA MANDIRI
Bank Account no.: 120-0004031808,
Bank Mandiri - Cabang Cempaka Putih
Jakarta, INDONESIA
INSTRUCTORS
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The Instructors for this short course will be given by expert in
certain field that is:
Dr.Ir. Slameto Wiryolukito& TEAM
Dr. Ir. Slameto Wiryolukito pprofessional experience: risk
assessment, material selections, failure analysis for oil and gas
companies such as; ConocoPhillips, Vico, BP, CNOOC, Exxonmobil, etc.
His specialization is material development for high temperature and
high corrosive conditions. Since 1982 he has been actively teaching
in undergraduate and master program in Mechanical Engineering
Department of Bandung Institute of Technology (ITB). He is a task
force member for Aircraft Accident Investigation Council (AAIC). He
got PhD from Materials Engineering Illinois Institute of technology,
Chicago, USA in 1994.
