Ipea Api579

The API 579 Fitness-for-Service
Standard The Current State of

Technology and a Ten Year Look
Ahead
10th Annual IPEIA (formerly NPEC) Conference
Banff Centre in Banff Alberta, Canada
February 1 3, 2006
Robert Brown, P.E.
Presentation Outline
Introduction
API 579 Development Background
Overview of API 579
New Joint API and ASME FFS Standard
Planned Developments for API/ASME 579
Overview of API/ASME 579-2006
Future Enhancements Following the 2006 Publication of
API/ASME 579
Technical Basis and Validation of API/ASME 579 FFS
Assessment Methods
Understanding of Damage Mechanisms
In-Service Inspection Codes and Fitness-For-Service
Fitness-For-Service and RBI - Complementary Technologies
Harmonizing Pressure Vessel Design and Fitness-For-Service
Summary
Introduction
The ASME and API construction codes do not provide
rules to evaluate a component containing a flaw or
damage that results from operation after initial
commissioning
Fitness-For-Service (FFS) assessments are quantitative
engineering evaluations that are performed to
demonstrate the structural integrity of an in-service
component containing a flaw or damage
API 579 was developed to evaluate flaws and damage
associated with in-service operation
API 579 assessment procedures were not originally
intended to evaluate fabrication flaws; however, these
procedures have been used for this purpose by many
Owner-Users
Introduction
If the damage mechanism cannot be identified, then a
FFS assessment should not be performed per API 579
Identification of damage mechanism is the key
component in the FFS assessment
Firm understanding of the damage mechanism is required
to evaluate the time-dependence of the damage
Time-dependence of damage is required to develop a
remaining life and inspection plan
API 579 provides guidance for conducting FFS

assessments using methods specifically prepared for
equipment in the refining and petrochemical industry;
however, this document is currently being used in
other industries such as the fossil utility, pulp & paper,
food processing, and non-commercial nuclear

APIs Definition of Fitness-For-Service
An FFS assessment is a multi-disciplinary engineering

analysis of equipment to determine whether it is fit for
continued service, typically until the next shutdown
The equipment may contain flaws, not met current
design standards, or be subjected to more severe
operating conditions than current design
The product of a FFS assessment is a decision to run as
is, monitor, alter, repair, or replace; guidance on an
inspection interval is also provided
FFS assessments consist of analytical methods (mainly
stress analysis) to assess flaws and damage

Need for FFS Standardization
Plant safety and Compliance with US OSHA 1910
Process Safety Management (PSM) Legislation
Operation of aging facilities
Maintaining safe, reliable operations with an increase in
run-lengths, increase in severity of operations and/or
decrease in shut-down periods
Rationalizing flaws found by more rigorous in-service
inspections than those conducted during original
construction
Refining and petrochemical industry is unique due to
the wide variety of processes and operating conditions,
materials of construction, and damage mechanisms
Standardization facilitates acceptance by jurisdictions

MPC FFS JIP Program Overview
Joint Industry Project (JIP) started in 1990 under The
Materials Properties Council (MPC)
Technology development focus
Base resource document and computer software
developed
Information disseminated to public through technical
publications and symposia
Technology developed provides basis for API 579
Continued sponsorship by owner-users and funding
support from API indicates high level of interest in FFS
MPC FFS JIP continues to develop new FFS technology
that is subsequently incorporated into API 579
Overview of API 579

General
Applicable to pressurized components in pressure

vessels, piping, and tankage (principles can also be
applied to rotating equipment)
Highly structured document with a modular
organization based on flaw type/damage condition to
facilitate use and updates
Multi-level assessment - higher levels are less
conservative but require more detailed analysis/data
Level 1 - Inspector/Plant Engineer
Level 2 - Plant Engineer
Level 3 - Expert Engineer
Overview of API 579

General
Identifies data requirements, applicability and

limitations of assessment procedures, and acceptance
criteria
Contains flow charts, figures, and example problems to
simplify use of the assessment procedures
Provides recommendations for in-service monitoring
and/or remediation for difficult situations
Provides recommendations for stress analysis
techniques, NDE, and sources for materials properties
Requires a remaining life to be evaluated; remaining
life is the basis for the inspection interval
Overview of API 579

General
General FFS assessment procedure used in API 579 for

all flaw types is provided in Section 2 that includes the
following steps:
Step
Step
Step
Step
Step
Step
Step
Step
1
2
3
4
5
6
7
8
Flaw & damage mechanism identification

Applicability & limitations of FFS procedures
Data requirements
Assessment techniques & acceptance criteria
Remaining life evaluation
Remediation
In-service monitoring
Documentation
Some of the steps shown above may not be necessary

depending on the application and damage mechanism
10
Overview of API 579

Contents
API 579 originally released in 2000: Nine flaws and

damage conditions are covered with supporting
appendices
Organized to facilitate use and updates
Section covering overall assessment procedure
Separate sections for each flaw type/condition
Consistent organization within each section
Information common to more than one section placed in
appendices
Self-contained document - do not need to purchase

other API standards to perform an assessment
11
Overview of API 579

Contents
Main Sections
Section 1 - Introduction
Section 2 - FFS Engineering Evaluation Procedure
Section 3 - Assessment of Equipment for Brittle Fracture
Section 4 - Assessment of General Metal Loss (tm < tmin - large area)
Section 5 - Assessment of Localized Metal Loss (tm < tmin - small area)
Section 6 - Assessment of Pitting Corrosion
Section 7 - Assessment of Blisters and Laminations
Section 8 - Assessment of Weld Misalignment and Shell Distortions
Section 9 - Assessment of Crack-Like Flaws
Section 10 - Assessment of Equipment Operating in the Creep Regime

(Draft version)
Section 11 - Assessment of Fire Damage
12
Overview of API 579

Contents
Appendices
Appendix A - Thickness, MAWP, and Stress Equations for a FFS

Assessment
Appendix B - Stress Analysis Overview for a FFS Assessment
Appendix C - Compendium of Stress Intensity Factor Solutions
Appendix D - Compendium of Reference Stress Solutions
Appendix E - Residual Stresses in a FFS Evaluation
Appendix F - Material Properties for a FFS Assessment
Appendix G - Deterioration and Failure Modes
Appendix H - Validation
Appendix I - Glossary of Terms and Definitions
Appendix J - Technical Inquires
13
Overview of API 579
Relationships to Other FFS Standards

The API Committee on Refinery Equipment (CRE) Task Group
responsible for development of API 579 reviewed internal
corporate methods, international standards and publications,
and incorporated appropriate technology
In most cases, modifications to existing or development of
new FFS methods were required
API Level 3 Assessments permit use of alternative FFS
procedures. For example, Section 9 covering crack-like flaws
provides reference to British Energy R-6, BS-7910, EPRI Jintegral, and other published methods
The API Task Group is working to set up technical liaisons with
other international FFS standard writing bodies (e.g. FITNET)
14

API and ASME have agreed to form a joint committee
to produce a single FFS Standard that can be used for
pressure-containing equipment
API 579 will form the basis of the new co-branded
API/ASME standard that will be produced by this
committee
The initial release of the new co-branded standard
designated as API/ASME 579 will occur in June, 2006
15

The second edition of API 579 and the new API/ASME
joint standard will include all topics currently contained
in API 579 and will also include new parts covering FFS
assessment procedures that address unique damage
mechanisms experienced by other industries
The agreement to produce a joint standard on FFS
technology is a landmark decision that will permit the
focusing of resources in the US to develop a single
document that can be used by all industries
In addition, a joint FFS standard will help avoid
jurisdictional conflicts and promote uniform acceptance
of FFS technology
16
New Developments for API/ASME 579

To avoid confusion with other ASME B&PV Codes and
Standards, Sections in API 579 are being renamed to
Parts
New Enhancements Existing Sections and New Parts
Part 5 Assessment of Local Thin Areas, assessment procedures
for gouges being relocated to Part 12
Part 7 Assessment of Blisters and HIC/SOHIC Damage,
assessment procedures for HIC/SOHIC damage have been added
Part 8 Assessment of Weld Misalignment and Bulges,
assessment procedures for bulges being modified (in progress),
assessment procedures for dents being relocated to Part 12
Part 10 Assessment of Equipment Operating in the Creep Range,
assessment procedures for remaining life calculations for
components with or without crack-like flaws are provided
Part 12 Assessment of Dents, Gouges, and Dent-Gouge
Combinations, new Part
Part 13 Assessment of Laminations, new Part
17

New Enhancements Existing and New Appendices
Appendix B Stress Analysis Overview for a FFS Assessment,
complete rewrite to incorporate new elastic-plastic analysis
methods and fatigue evaluation technology developed for the
ASME Div 2 Re-write Project
Appendix C Compendium of Stress Intensity Factor Solutions,
new stress intensity factor solutions for thick wall cylinders,
through wall cracks in cylinders and spheres, holes in plates
Appendix E - Compendium of Residual Stress Solutions, complete
rewrite to incorporate new solutions developed by PVRC Joint
Industry Project
Appendix F Material Properties for a FFS Assessment, new
fracture toughness estimation methods and stress-strain curve
model incorporated
Appendix H Technical Basis and Validation of FFS Procedures
Appendix K Crack Opening Areas, new appendix covering crack
opening areas for through-wall flaws in cylinders and spheres
18

New Enhancements Example Problems
All example problems will be removed and placed in a
separate example problems manual
Additional example problems with more background
information will be provided
Future Enhancements (after 2006) - New Parts

Assessment of Hot-Spots
Assessment of HTHA (High Temperature Hydrogen Attack)
Damage
Assessment of Fatigue Damage
19

Part 3: Brittle Fracture
Provides guidelines for evaluating the resistance to brittle
fracture of existing carbon and low alloy steel pressure
vessels, piping, and storage tanks
+ Screening of equipment for susceptibility (Level 1 & 2)
+ Detailed assessment using fracture mechanics (Level 3 per
Part 9)
+ Assessment typically performed on a weld-joint by weld joint
basis
The purpose of this assessment is to avoid a catastrophic

brittle fracture failure consistent with ASME Code, Section
VIII design philosophy; however, it does not ensure
against service-induced cracks resulting in leakage or
arrest of a running brittle fracture
20

Part 3: Brittle Fracture Changes
Minimal changes to existing
API 579 methodology in
Section 3; Changes in
structure to improve user
friendliness
Minimum Allowable
Temperature (MAT) -Single
temperature or envelope of
temperature as function of
pressure
Critical Exposure
Temperature (CET) -Lowest
metal temperature at
primary stress > 8 ksi
21

Part 4: General Metal Loss
Covers FFS for pressurized components subject to
general metal loss resulting from corrosion and/or
erosion
+ Procedures can be applied to both uniform and local metal
loss
+ Procedures provide an MAWP or MAT
Assessment procedures in this section are based on a

thickness averaging approach
+ Suitable result is obtained when applied to uniform metal loss
+ For local or non-uniform metal loss, the Part 4 thickness
averaging approach may produce overly conservative results;
the assessment procedures of Part 5 (FFS rules covering local
metal loss) can be utilized to reduce the conservatism in the
analysis
22

Part 4: General Metal Loss - Changes
Minimal changes to existing API 579 methodology
Change from tmin to trd
Existing
New
23

Part 5: Local Metal Loss
The assessment procedures of Part 5 are for the analysis
of local metal loss or Local Thin Areas (LTA)
The procedures of Part 4 are for general (uniform and
non-uniform) metal loss
24

Part 5: Local Metal Loss - Changes
Level 1 Assessment
+ Longitudinal plane - screening curve changed to family of
curves f(RSFa, E); groundwork for adapting to different Codes
+ Circumferential plane - screening curve changed to family of
curves f(RSFa, E); Includes 20% of allowable as bending
stress; more conservative
Level 2 Assessment
+ Longitudinal plane - New Folias factor; no limitation on length
of LTA (was lambda<5)
+ Circumferential plane - Added circumferential Folias factor
to analysis; changed acceptability criteria from yield basis to
allowable stress basis
25

Part 5: Local Metal
Loss - Changes
Stiffening Rings
New Level 2 Assessment

procedure is provided
for evaluating cylindrical
shells with LTAs subject
to external pressure
New method based on
idealized cylindrical shell
Basic equation is:
n
MAWPr
L
i 1
n
Actual Cylindrical Shell
LT
Idealized Cylindrical Shell

t1
t2
t3
t4
L1
L2
L3
L4
Li
e
P
i 1 i
26

Part 6: Pitting
The assessment procedures in Part 6 were developed to
evaluate metal loss from pitting corrosion
Pitting is defined as localized regions of metal loss which
can be characterized by a pit diameter on the order of
the plate thickness or less, and a pit depth that is less
than the plate thickness
Assessment procedures are provided to evaluate both
widespread and localized pitting in a component with or
without a region of metal loss
The procedures can be used to assess a damaged array
of blisters as described in Part 7
27

Part 6: Pitting - Changes
Level 1 Screening
+ Pitting Charts
* Visual FFS Assessment (similar to ASME Code porosity charts),
* Current Level 1 and existing Level 2 merged into new Level 2
+ Data for Assessment

* Include a photograph with reference scale and/or rubbing of the
surface
* Maximum pit depth
* Cross section of UT thickness scan can also be used
28

Part 6: Pitting Changes
Pitting Charts
+ FFS by visually
comparing pit chart to
actual damage plus
estimate of maximum
pit depth
+ Pit charts provided for
a different pitting
damages measured as
a percentage of the
affected area in a 6
inch by 6 inch
+ RSF provided for each
pit density and four
w/t ratios (0.2, 0.4,
0.6, 0.8)
Pitting Chart API 579 Grade 4 Pitting
29

Part 6: Pitting - Changes
Level 1 Screening
+ Determine ratio of remaining wall thickness to the future
wall thickness in pitted region:
+ Find pitting chart that matches damage and determine RSF
Rwt
trd wmax
tc
where,
trd
thickness away from pitted region
wmax
max pit depth
tc
future corroded thickness
30

Part 7: Hydrogen Blisters and HIC/SOHIC (New)
Provides assessment procedures for low strength ferritic
steel pressurized components with hydrogen induced
cracking (HIC) and blisters, and stress oriented HIC
(SOHIC) damage
Excludes:
+ Sulfide stress cracking (SSC)
+ Hydrogen embrittlement of high strength steels (Brinnell
>232)
+ Excludes methane blistering
+ HTHA
31

Various forms of damage all related to hydrogen being
charged into the steel from a surface corrosion reaction
in an aqueous H2S containing environment.
Hydrogen Blistering
+ Hydrogen blisters form bulges on the ID, the OD or within the
wall thickness of a pipe or pressure vessel.
+ Atomic H collects at a discontinuity (inclusion or lamination)
in the steel
+ H atoms form molecular hydrogen which is too large to
diffuse out; pressure builds to excess of YS and local
deformation occurs, forming a blister
Hydrogen Induced Cracking (HIC)

+ Hydrogen blisters can form at different depths from the
surface. And may develop cracks that link them together.
+ Interconnecting cracks between the blisters often are
referred to as stepwise cracking
32

Stress Oriented Hydrogen Induced Cracking (SOHIC)
+ Similar to HIC, but more damaging
+ Arrays of cracks stacked on top of each other, resulting in
through-thickness crack
+ Seen mostly in HAZ, due to residual stresses
Zero degree
scan overlaid
with 45 degree
shearwave
results
(provided by
Westech
Inspection, Inc.)
33

Level 2 HIC Assessment
Strength check Determine RSF by
considering region
as LTA with reduced
strength (20%)
Fracture check Evaluate HIC as a
crack-like flaw per
Part 9
34

Part 8: Weld misalignment And Shell Distortions
The procedures in this part can be used to assess weld
misalignments and shell distortions in components made
up of flat plates; cylindrical, conical, and spherical shells;
and formed heads.
Weld Misalignment centerline offset, angular
misalignment (peaking), and a combination of centerline
offset and angular misalignment
Shell Distortion Categories include:
+ General Shell Distortion
+ Out-of-roundness
+ Bulge
35

Part 8: Weld misalignment And Shell Distortions Changes
Pseudo code provided for computation of Fourier Series
coefficients for analysis of out-of-roundness radius data
Assessment procedure rules for bulges deleted, new rules
currently being developed by MPC FFS JIP, will not be
included in the 2006 edition
36

Part 9: Crack-Like Flaws
Crack-like flaws are planar flaws which are predominantly
characterized by a length and depth, with a sharp root
radius, the types of crack-like flaws are
+ Surface breaking
+ Embedded
+ Through-wall
In some cases, it is conservative and advisable to treat

volumetric flaws such as aligned porosity or inclusions,
deep undercuts, root undercuts, and overlaps as planar
flaws, particularly when such volumetric flaws may
contain microcracks at the root
Grooves and gouges with a sharp root radius are
evaluated using Section 9, criteria for the root radius is in
Section 5
37

Part 9: Crack-Like Flaws
The assessment procedures in Part 9 are based on a
fracture mechanics approach considering the entire range
of material behavior
+ Brittle fracture
+ Elastic/plastic fracture
+ Plastic collapse
Information required to perform an assessment is

provided in Part 9 and the following Appendices
+
+
+
+
Appendix
Appendix
Appendix
Appendix
C - Stress Intensity Factor Solutions

D - Reference Stress Solutions
E - Residual Stress Solutions
F - Material Properties
38

Part 9: Crack-Like Flaws - Changes
Appendix C - Stress Intensity Factor (K) Solutions
+ Improved K solutions over larger range of geometries (Small
R/t)
+ K solutions for shallow cracks a/t<0.2 improved
Appendix E New Residual Stress Solutions based on

PVRC Residual Stress JIP research
Appendix F - Material Properties, new methods to
estimate fracture toughness based on MPC FFS JIP
research co-funded by API
39

Part 10: Creep (New)
API 579, Part 10 provides assessment procedures for
pressurized components operating in the creep range
The temperature above which creep needs to be
evaluated can be established using a Level 1 Assessment
Assessment procedures for determining a remaining life
are provided for components with and without a cracklike flaw subject to steady state and/or cyclic operating
conditions
The procedures in this Part can be used to qualify a
component for continued operation or for re-rating
40

Level 1 Assessment - Limitations
+ Component has been constructed to a recognized code or
standard
+ A history of the component can be provided covering both
past and future operating conditions
+ The component has been subject to less than 50 cycles of
operation including startup and shutdown conditions
+ The component does not contain a flaw such as an LTA,
pitting or crack-like flaw
+ Component has not been subject to fire damage or another
overheating event that has resulted in a significant change in
shape such as sagging or bulging, or excessive metal loss
from scaling
+ The material meets or exceeds minimum hardness and
carbon content limitations
41

Level 1 Assessment Calculations: single operating condition
STRESS, KSI
100
250,000 HRS
25,000 HRS
2,500 HRS
250 HRS
25 HRS
10
1
600
700
800
900
1000
1100
1200
TEMPERATURE, F
42

Level 1 Assessment Calculations: multiple operating condition
DAMAGE ISOTHERMS
S
T
R
E
S
S
,K
S
I
10.00
1.00
1E-08
1E-07
1E-06
1E-05
1E-04
1E-03
750,F
775,F
800,F
825,F
850,F
875,F
900,F
925,F
950,F
975,F
1000,F
1025,F
1050,F
1075,F
D R t
j
c
j
c
j
se
Dctotal Dcj 0.25

j 1
DAMAGE RATE, FRACTIONAL DAMAGE/HR
43

Level 2 Assessment - Limitations
+ Component has been constructed to a recognized code or
standard
+ A history of the component can be provided covering both
past and future operating conditions
+ The component has been subject to less than 50 cycles of
operation including startup and shutdown conditions
+ The component does not contain a flaw such as an LTA,
pitting or crack-like flaw
Level 2 Assessment - Calculations

+ Analysis (i.e. FEA) used to determine temperature and stress
as a function of time
+ Material data and damage rule used to determine
acceptability for continued operation
+ Method based on MPC Project Omega JIP
44

Part 11: Fire Damage
Covers assessment procedures for evaluating pressure
vessels, piping and tanks subjected to flame
impingement and the radiant heat of a fire
Assessment procedures address the visually observable
structural degradation of components and the less
apparent degradation of mechanical properties, such as
strength, ductility, and toughness
Assessment procedures may also be used to evaluate
process upsets due to a chemical reaction within process
vessels
Part 11: Fire Damage - Changes

Reference provided to new Part 10 to evaluate creep
damage resulting from a fire
45

Part 12: Dents, Gouges, and Dent-Gouge
Combinations (New)
Assessment procedures for pressurized components
containing dents, gouges, or dent-gouge combinations
resulting from mechanical damage
Dent An inward or outward deviation of a cross-section
of a shell member from an ideal shell geometry that is
characterized by a small local radius or notch
Gouge An elongated local removal and/or relocation of
material from the surface of a component caused by
mechanical means that results in a reduction in wall
thickness; the material may have been cold worked in
the formation of the flaw
Dent-Gouge Combination A dent with a gouge present
in the deformed region
46

Part 12: Dents, Gouges, and Dent-Gouge
Combinations (New)
Assessment procedures permit calculation of MAWP or
MFH
Level 1 Assessment Procedures based on simple
screening criteria
Level 2 Assessment Procedures require some stress
analysis, fatigue calculation method included for dent and
dent-gouge combinations
47

Part 13: Laminations (New)
Covers assessment procedures for pressurized
components with laminations, excluding HIC or SOHIC
damage
Laminations are defined as a plane of non-fusion in the
interior of a steel plate that results during the steel
manufacturing process
Existing assessment procedures in Part 7 will be
significantly updated
48

Appendices updates previously discussed have been
completed
Appendix B Stress Analysis Overview for a FFS Assessment Change, complete rewrite to incorporate new elastic-plastic
analysis methods and fatigue evaluation technology developed for
the ASME Div 2 Re-write Project
Appendix C Compendium of Stress Intensity Factor Solutions Change, new stress intensity factor solutions for thick wall
cylinders, through wall cracks in cylinders and spheres, holes in
plates
Appendix E - Compendium of Residual Stress Solutions - Change,
complete rewrite to incorporate new solutions developed by PVRC
Joint Industry Project
Appendix F Material Properties for a FFS Assessment - Change,
new fracture toughness estimation methods and stress-strain
curve model incorporated
Appendix H Technical Basis and Validation of FFS Procedures
NEW, technical basis document that provides an overview of the
technical background and validation with essential references
Appendix K Crack Opening Areas - NEW, appendix covering
crack opening areas for through-wall flaws in cylinders and
spheres
49
Future Enhancements After the 2006

Publication of API/ASME 579
Technology Development Efforts Currently Underway
Documentation of validation of new assessment procedures
for HIC/SOHIC damage (2006)
Allowable Remaining Strength Factor (RSFa) calibration
based on original construction code (2006)
Assessment of local thin areas (2007)
+ Development of a new method for computing the RSF factor for
both Level 1 and Level 2 Assessments
+ Development of new LTA-to-LTA spacing criteria
+ Development of new LTA-to-structural discontinuities spacing
criteria
+ Development of new rules for assessment of local thin areas at
nozzles and other shell discontinuities
Completion of Example Problems Manual (2007)
50

Technology Development Efforts Currently Underway
Assessment Procedures for bulges (2007)
Assessment of crack-like flaws (2007)
+ New PSF (Partial Safety Factors) for crack-like flaws,
introduction of PSFs for LTAs
+ Development of new reference stress solutions based on JIntegral Technique
+ Evaluation of weld mismatch effects
Assessment procedures for HTHA (2007)

Assessment procedures for hot-spots (2008)
Assessment of damage in cast iron components (paper
mill dryers) (2008)
51

Future Technology Needs
Improved fracture toughness evaluation for in-service
materials
+
+
+
+
Carbon steel and low alloys

Environmental effects (e.g. hydrogen)
Temperature dependency
Statistical evaluation
Improved assessment procedures for dents and dentgouge combinations

+ Removal of geometry restrictions
+ Coverage of more materials
+ Coverage of more loading types
Evaluation of material toughness effects on the burst

pressure of components with non-crack-like flaws (i.e.
LTAs, pitting)
52

Assessment Procedures for Crack-Like Flaws
+ FAD dependency on stress-strain curve
+ Evaluation of pressure test and warm pre-stress effects
+ Improved crack growth models, including data, considering
environmental efforts
Assessment Procedures for Fatigue

+ Multiaxial fatigue
+ Cycle counting
+ Environmental effects
Assessment Procedures for Creep Damage

+ Include primary creep in MPC Project Omega Creep Model
+ Creep damage from triaxial stress states
+ Development of new procedures to evaluate creep-fatigue
damage
+ New procedures to evaluate creep-buckling
53

Improved Stress-Strain Models
+ Temperature Effects
+ Loading Rate Effects
+ Cyclic Stress-Strain Curves
Introduction of partial safety factors for other types of

damage (i.e. LTA, pitting)
Additional stress intensity factor solutions for common
pressurized component geometries (e.g. cracks at
nozzles)
54
Technical Basis and Validation of

API/ASME 579 FFS Assessment
Methods
The API CRE FFS and Joint API/ASME Committees are
committed to publishing the technical basis to all FFS
assessment procedures utilized in API 579 in the public
domain
It is hoped that other FFS standards writing committees
adopt the same policy as it is crucial that FFS knowledge
remains at the forefront of technology on an international
basis to facilitate adoption by jurisdictional authorities
The new API 579 Appendix H of API 579 provides an
overview of technical basis and validation with related
references organized by damage type, the references are
published in a series of WRC Bulletins and technical papers
55

Methods
WRC Bulletins Published
Review of Existing Fitness-For-Service Criteria for Crack-Like Flaws
(WRC 430)
Technologies for the Evaluation of Non-Crack-Like Flaws in
Pressurized Components - Erosion/Corrosion, Pitting, Blisters, Shell
Out-of-Roundness, Weld Misalignment, Bulges, and Dents in
Pressurized Components (WRC 465)
Development of Stress Intensity Factor Solutions for Surface and
Embedded Cracks in API 579 (WRC 471)
Stress Intensity and Crack Growth Opening Area Solutions for
Through-wall Cracks in Cylinders and Spheres (WRC 478)
Recent Progress in Analysis of Welding Residual Stresses (WRC 455)
Recommendations for Determining Residual Stresses in Fitness-ForService Assessments (WRC 476)
Master S-N Curve Method for Fatigue Evaluation of Welded
Components (WRC 474)
56

Methods
WRC Bulletins Pending
Compendium of Temperature-Dependent Physical Properties for
Pressure Vessel Materials (WRC 503)
An Overview and Validation of The Fitness-For-Service Assessment
Procedures for Locally Thin Areas in API 579 (WRC 505)
57

Methods
WRC Bulletins In Preparation
An Overview of The Fitness-For-Service Assessment Procedures

for Pitting Damage in API 579
An Overview of the Fitness-For-Service Assessment Procedures

for Weld Misalignment and Shell Distortions in API 579
An Overview and Validation of the Fitness-For-Service

Assessment Procedures for Crack-Like Flaws in API 579
An Overview and Validation of Residual Stress Distributions for

Use in the Assessment Procedures of Crack-Like Flaws in API
579
An Overview and validation of the Fitness-For-Service Rules for

the Assessment of HIC/SOHIC Damage in API 579
58

Methods
WRC Bulletins In Preparation
MPC Project Omega and Procedures for Assessment of Creep
Damage in API 579
Development of a Local Strain Criteria Based on the MPC
Universal Stress-Strain Equation
Update on the Master S-N Curve Method for Fatigue Evaluation
of Welded Components
59
Understanding of Damage
Mechanisms
The first step in a Fitness-For-Service assessment
performed in accordance with API 579 is to identify the
flaw type and associated damage mechanism
Appendix G in API 579 provides basic information to assist
the practitioner in this step
The following WRC Bulletins have been produced to
provide the practitioner with in-depth information
Damage Mechanisms Affecting Fixed Equipment in the Pulp and
Paper Industry (WRC 488)
Damage Mechanisms Affecting Fixed Equipment in the Refining
Industry (WRC 489 & API RP 571)
Damage Mechanisms Affecting Fixed Equipment in the Fossil
Electric Power Industry (WRC 490)
60
In-Service Inspection Codes

and Fitness-For-Service
Jurisdictional acceptance provided by reference from
in-service inspection codes in the US
API 510 Vessels

API 570 Piping
API 653 Tankage
ANSI/NB-23 Vessels & Boilers
Status of reference from US inspection codes is as

follows:
API 510 Reference in 8th Edition, 2nd Addendum

API 570 Reference in 2nd Edition, 2nd Addendum
API 653 Reference to appear in 3rd Edition, 1st Addendum
ANSI/NB-23 Reference in Introduction of 2001 Addendum
Working to achieve recognition by other international

in-service inspections codes
61
In-Service Inspection Codes

and Fitness-For-Service
Reactive FFS can be used to assess damage found
during an inspection; provides basis for run, repair, or
replace decision
Proactive FFS can be used prior to shut-downs to help
develop inspection plans (e.g. determine maximum
permissible flaws sizes)
The remaining life is determined as part of an FFS
assessment:
Used to establish an inspection interval
Half-life or similar concepts can be used
Snap-Shot approach to FFS is not adequate, an evaluation of the
time dependency of damage is required
62
Fitness-For-Service and RBI Complimentary Technologies

Assessment of damage in many of the RBI methods
currently being used is needs updating; is not consistent
with FFS assessment procedures
Documented and validated FFS methods for flaw and
damage assessment may be used to establish a probability
of failure as a function of time by considering uncertainties
in the damage model and independent variables
The resulting probably of failure can be combined with a
consequence model to produce an estimate of risk as a
function of time
Time dependency of risk permits development of an
inspection plan
Work is underway to integrate API 579 with API 581
63
Harmonizing Pressure Vessel Design and

Fitness-For-Service
To remain technically competitive, and to facilitate
incorporation of new technology and future updates, ASME is
developing a new pressure Vessel Code; this code will replace
the existing Section VIII, Division 2 Code
The new code is being developed primarily to address design
and fabrication of engineered pressure vessels (as typically
used in the refining and petrochemical industry); will result in
significant cost savings
The new code is consistent with developments in Europe
Objective to develop a new organization and introduce a clear
and consistent writing style to facilitate use; consistent with
API-579 philosophy
Shared technology between API-579 and new design Code.
Draft version of new Code is complete; work is underway to

ballot the Div 2 Rewrite in 2006
64
Summary
Fitness-For-Service (FFS) assessments are quantitative
engineering evaluations that are performed to demonstrate the
structural integrity of an in-service component containing a
flaw or damage
API and ASME have agreed to form a joint committee to
produce a single FFS Standard, API/ASME 579, that can be
used for pressure-containing equipment
Permits focusing of resources in the US to develop a single
document that can be used by all industries
Helps avoid jurisdictional conflicts and promotes uniform
acceptance of FFS technology
The 2006 edition of API/ASME 579 represents a significant

update in assessment procedures
The technical basis and validation of the API/ASME 579 FFS
assessment procedures will be published in the public domain
API/ASME 579 FFS assessment methods have been integrated
with API & NBIC inspection codes and will be integrated into
API RBI technologies
Significant technical development work remains and a work
plan is being formulated
65
Robert Brown, P.E.

FFS Team Leader
216-283-6015
rgbrown@equityeng.com
20600 Chagrin Blvd. Suite 1200

Shaker Heights, OH 44122 USA
Phone: 216-283-9519 Fax: 216-283-6022
www.equityeng.com
66

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The API 579 Fitness-for-Service

Standard The Current State of

Robert Brown, P.E.

API 579 provides guidance for conducting FFS

API 579 Development Background

An FFS assessment is a multi-disciplinary engineering

API 579 Development Background

API 579 Development Background

Overview of API 579

Applicable to pressurized components in pressure

Overview of API 579

Identifies data requirements, applicability and

Overview of API 579

General FFS assessment procedure used in API 579 for

Flaw & damage mechanism identification

Some of the steps shown above may not be necessary

Overview of API 579

API 579 originally released in 2000: Nine flaws and

Self-contained document - do not need to purchase

Overview of API 579

Section 2 - FFS Engineering Evaluation Procedure

Section 3 - Assessment of Equipment for Brittle Fracture

Section 6 - Assessment of Pitting Corrosion

Section 7 - Assessment of Blisters and Laminations

Section 8 - Assessment of Weld Misalignment and Shell Distortions

Section 9 - Assessment of Crack-Like Flaws

Section 10 - Assessment of Equipment Operating in the Creep Regime

Section 11 - Assessment of Fire Damage

Overview of API 579

Appendix A - Thickness, MAWP, and Stress Equations for a FFS

Appendix B - Stress Analysis Overview for a FFS Assessment

Appendix C - Compendium of Stress Intensity Factor Solutions

Appendix D - Compendium of Reference Stress Solutions

Appendix E - Residual Stresses in a FFS Evaluation

Appendix F - Material Properties for a FFS Assessment

Appendix G - Deterioration and Failure Modes

Appendix I - Glossary of Terms and Definitions

Appendix J - Technical Inquires

Overview of API 579

Relationships to Other FFS Standards

New Joint API and ASME FFS Standard

New Joint API and ASME FFS Standard

New Developments for API/ASME 579

New Developments for API/ASME 579

New Developments for API/ASME 579

Future Enhancements (after 2006) - New Parts

Overview of API/ASME 579-2006

The purpose of this assessment is to avoid a catastrophic

Overview of API/ASME 579-2006

Overview of API/ASME 579-2006

Assessment procedures in this section are based on a

Overview of API/ASME 579-2006

Overview of API/ASME 579-2006

Overview of API/ASME 579-2006

Overview of API/ASME 579-2006

New Level 2 Assessment

Actual Cylindrical Shell

Idealized Cylindrical Shell

Overview of API/ASME 579-2006

Overview of API/ASME 579-2006

+ Data for Assessment

Overview of API/ASME 579-2006

Pitting Chart API 579 Grade 4 Pitting