Training Certificate

Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees.

Course Introduction

The design codes and standards for piping and pressure vessels provide rules for design, fabrication, inspection and testing of new systems. Piping and pressure vessels do degrade while in-service due to deficiencies from original fabrication or due to different causes of degradation.  Fitness-for-Service (FFS) assessments are quantitative engineering evaluation performed to determine the structural integrity of an in-service systems containing a flaw or damage. The FFS help engineers to make run-repair-replace decisions to help ensure that the system in-service can continue to operate safely.

Fitness-for-Service intends to ensure safety of plant personnel and public while older equipment continues to operate, to provide technically sound fitness-for-service assessment procedure to ensure that different service provide furnish consist life prediction, and to help optimize maintenance and operation of existing facilities.

FFS is an integration of three disciplines; these are materials, inspection, and mechanical analysis.

The course will discuss the three technological triad required for fitness-for-service assessment, and apply that on the piping and pressure vessels systems. All of the above will be presented in connection with the related codes and standards.

Examples will be presented using the known methods and programs. Delegates are asked to bring with them their own laptops to practice some of such exercises.

Course Objective

• The participant will learn the importance of FFS for piping systems and pressure vessels
• The participant will learn the principles of FFS, and how to apply it on Piping system and Pressure vessels.
• The participant will learn where to find and how to calculate data necessary for FFS application
• The participant will learn how to use the results of FFS to take right decision concerning the operation, shutdown, interval of inspection, repair of the existing in-service piping
• The participant will learn how to evaluate the integrity and remaining life of piping systems and pressure vessels.
• The participant will have a chance to practice some the FFS assessment methods during the course.

Suitable For

Mechanical engineers, process plant and piping / pressure vessels engineers and inspectors responsible for design, installation, operation, integrity and maintenance of piping systems and pressure vessels are encouraged to attend this course.

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work & Practical Exercises
• 20% Videos & General Discussions

Course Content

Ch 1 Piping and Pressure Vessels Deterioration and Failure Modes

            Pre-Service Deficiencies

            In-Service deterioration and damage

                        General Metal Loss due to Corrosion and/or Erosion

                        Localized Metal Loss due to Corrosion and/or Erosion

                        Surface Connected Cracking

                        Subsurface Cracking and Microfissuring/Microvoid Formation

                        Metallurgical Changes

Ch 2 Material Properties for FFS assessment

            Strength Parameters

                        Yield and Tensile strength

                        Flow Stress

                        Stress-Strain relationship

            Physical properties

                        Elastic Modulus

                        Poisson’s Ratio

                        Coefficient of Thermal expansion

            Fatigue Toughness

                        Fracture Toughness Parameters

                        Low bound fracture Toughness

                        Charpy V-Notch data

                        Fracture Toughness for in-service materials

                        Temper Embrittlement

            Crack Growth

                        Categories of Crack Growth

                        Fatigue Crack Growth Calculation

            Fatigue Curves

                        Smooth Bar test Specimens

                        Welded test specimens

            Creep Rupture

                        Creep Strain-Rate Data

                        Crack Initiation

                        Creep Crack Growth

Ch 3 Stress Analysis for FFS Assessment

            Stress Analysis Methods for a FFS

            Linear Elastic Stress Analysis Methods and Acceptance Criteria

            Nonlinear Elastic Plastic Stress analysis Methods and Acceptance Criteria

            Methods of Structural Stability

            Methods of Fatigue Evaluation

            FFS Assessment Using Finite Element Analysis        

Ch 4 Thickness, MAWP and Membrane Stress Equation for a FFS Assessment

            Calculation of Minimum Thickness

Calculation of MAWP (MFH)

Calculation of Membrane Stress

            Piping Components

            Pressure vessels Components

Ch 5 Fitness-For-Service Assessment

FFS Engineering Assessment Procedure

                        Date Requirement

                        Assessment Techniques

                        Acceptance Criteria

                        Remaining Life Evaluation

                        Remediation

                        In-Service Monitoring 

            Types of assessment

                        Assessment for Brittle Fracture

                        Assessment of General Metal Loss

                        Assessment of Local Metal Loss

                        Assessment of Pitting Corrosion

                        Assessment of Blisters and Laminations

                        Assessment of Crack-Like Flaws