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The Calculators here-in are tools designed for inspectors and engineer to rapidly and consistent with the required steps, validate pass/fail screening requirements of in-service systems found with defects using the methodology of API579-1 FFS in the applicable Level 1 and Level 2 scenarios as per applicable defects. It is not intended to replace provincial/state requirements, Design Code guidelines and user-owner risk profile models. It is not a detailed engineering analysis and not intended to be a comprehensive tool. The tool does not generally take into consideration advanced level assessments outside level 1 and Level 2 assessment approaches as well as several complex external loads and conditions that may exist on a pressure system. Use of this tool requires adequate knowledge of the steps and limitations as specified in the applicable design code and API579-1 code of the defect analysed and this tool. Detailed/Advanced engineering analysis (Level 3) are required when the limitations as detailed in the code relate to a system in question and where the software application specifies or states limitations of critical variables not accounted for. A competent engineer is responsible for assessing the design of the system and assuring that internal pressure is the proper design criteria for continued use. Engineering analysis, Good judgment and industry best practices should be used to assess the validity and applicability of the results obtained by this tool.

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Often times, Inspectors and engineers have to make prompt, accurate and sound decisions with respect to the general Mechanical Integrity and Structural Fitness for continued use of in-service systems (piping, Pressure Vessels, Tanks and peripheral) when indications are found and classified as defect WRT their design standards and operating conditions.

Currently, Plant, Reliability and Asset integrity engineers usually have to go through various standards and develop models to compute L1/L2 structural integrity assessments to make Go/No-Go calls during plant runtime and Outage work windows for continued running, repair, replace and required level of follow work. Nowadays, inspectors are becoming more engaged and required to make such calls too. This is usually time consuming and many times when challenged are found with may inconsistencies based on the risk tolerance of the engineer.

Another approach has been to involve 3rd party consultants with the expectation of advanced knowledge. It doesn't solve the problem of prompt delivery and comes often times with a high price tag as well as errors in modelling due to limited 1st hand field knowledge of the defect/system and interpreting customer inspection information while offsite.

The level of assessment, quality of the results and final decision directly affects the plants safety, Reliability, productivity and thus bottom-line. Industrywide (Chemical and Petrochemical) approximately 10% of defects require in-depth and advanced (Level 3) Fitness for Service evaluations which may involve custom modelling and FEA analysis. The other 90% need less rigor. A design standard and Level 1 or 2 fitness for service evaluation is appropriate and usually sufficient. The focus of Rapidsolve™ is these 90%.

Rapidsolve™ is developed to give prompt, accurate and consistent L1/L2 defect evaluation and results in minutes.
Rapidsolve™ is Modelled primarily around the API579-1 FFS and many years of engineering judgement. The code validations were done by certified engineers and SMEs using actual plants defect findings, and case scenarios in API579-1 and API579-2. A good understanding of the concept of FFS as specified in API597-1 is required to properly use and interpret the results using this application.

Rapidsolve™ is not intended to replace provincial/state requirements, Design Standard guidelines and user-owner risk profile models. It is not a detailed engineering analysis and not intended to be a comprehensive tool. The tool does not generally take into consideration outside level 1 and Level 2 assessment approaches as well as several complex external loads and conditions. Use of this tool requires adequate knowledge of the steps and limitations as specified in the applicable design standard and FFS-API579-1 standard of the defect analyzed. Engineering analysis plus Level 3 are required when the limitations as detailed in the standard relate to a system in question. The software entails the following features and level of assessment capabilities:

• Structural Integrity & fitness procedure for Defects & Damage Mechanisms.
• Prompt & Accurate Analysis. Visual Aids and graphs for defect illustration.
• Simple Go/No Go Step-wise screening for Repair-Rerate-Replace FFS decisions.
• Cloud based Access. No computer installation required. Free Updates!
• Assessment procedures Verified with known actual and verifiable cases.
• Review & Updates by SME Engineers and Inspectors using an MOC/SR process.

Brittle Fracture Part 3 (L1 & L2)

Assessment Procedure specified uses Method A and B Only of the reference code API579-1/ASME FFS-1. This explores evaluating the resistance to brittle fracture of existing carbon and low alloy steel pressure vessels, piping, and storage tanks. Criteria are provided to evaluate normal operating, start-up, upset, and shut-down conditions. Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

General Metal Loss Part 4 (L1 & L2)

Assessment procedures specified explores cases of general corrosion. Thickness data used for the assessment can be either point thickness readings or Grid detailed thickness profiles. When the Metal loss profile is not general, the method and approach in the assessment procedures of Part 5 are applicable. Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Local Metal Loss Part 5 (L1 & L2)

Assessment procedures specified explores cases of single Thin Ares, closely spaced Local Thin Areas LTSs and groove-like flaws. Thickness data used for the assessment can be either point thickness readings or detailed thickness profiles (Grid). The procedure can be utilized for assessments of stand-alone pits or blisters as per Part 6 and Part 7. When the Metal loss profile is not localized, the method and approach in the assessment procedures of Part 4 are applicable. Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Pitting Corrosion Part 6 (L1 & L2)

Assessment procedures specified explores cases to evaluate systems with widely scattered pitting, localized pitting. The procedure is also applicable for evaluating closely spaced blisters as provided for in Part 7. Procedure assessment condition exceptions: 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 are not covered Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Blisters and HIC/SOHIC Damage Part 7 (L1 & L2)

Assessment procedures specified explores cases to evaluate systems with isolated and closely spaced and multiple blisters and HIC/SOHIC Damage. The assessment is applicable for blisters and HIC/SOHIC damage located around weld joints and near structural discontinuities / transitions on the system / component as applicable. Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Weld Misalignment and Shell Distortions. Part 8

Assessment Procedure not specified for this class of defects.

Crack-Like Flaws Part 9 (L1)

Basic assessment procedures specified explores cases to evaluate crack-like flaws. Procedure exceptions: Application for systems with stress intensity factors and reference stress as well as residual stresses is not included. Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

High Temperature Operation and Creep Part 10 (L1 & L2)

Assessment procedures specified explores cases to evaluate systems operating within the creep range as well as the remaining life (Estimated remaining life and number of remaining cycles). Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Fire Damage Part 11

Assessment Procedure not specified for this class of defects.

Dent, Gouge, and Dent Gouge Combinations Part 12 (L1 & L2)

Assessment procedures specified explores cases to evaluate systems with dent, gouge, and dent gouge combinations in components. Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Laminations Part 13 (L1 &L2)

Assessment procedures specified explores cases to evaluate systems with laminations. The assessment is applicable for laminations located around weld joints and near structural discontinuities / transitions on the system / component as applicable. Procedure assessment condition exceptions: Systems under substantial supplementary loads, full vacuum conditions, and application when Impact Test Results Are Not Available. System Geometry: Cylindrical and Conical profile only.

Fatigue Part 14

Assessment Procedure not specified for this class of defects.

Pricing: RAPIDSOLVE™ is offered on various terms to support clients. To purchase a subscription, please contact tech@rapidsolve.ca

Applicable Sectors: Petro-Chemical & Energy. Expertise: Intermediate. Training Setup: Class.

Who should attend?

This course is designed for plant personnel who are engaged in design, inspection and maintenance and repair of fixed equipment. (Tanks, Pressure Vessels and piping). This would typically include experienced Unit Inspectors, Plant Engineers, Asset Integrity Specialist and engineers, Operations Engineers, Maintenance Engineers, Welding Engineers and allied personnel. A general working knowledge of this class of equipment, and their usual construction materials is a requirement to attend this course.

The training provides direction for performing flaw/defect assessments using API 579-1/ASME FFS recommended practices as it applies to fixed pressure equipment. The training is a hands-on approach with participants completing actual plant/field examples. This is aided using RAPIDSOLVETM; a FFS software application to further reinforces the presentation and understanding of solutions and outcomes of the assessment.

All participants will have individual 60 days' trial access to a cloud based software application which aids FFS assessments.

Upon Completion of this training, participants will:

• Have a baseline understanding of the Methods & Techniques of Fitness for Service as per API 579-1/ASME FFS.
• Better understand damage mechanisms, flaw/defect extent and impacts to pressure equipment.
• Multiple approaches to assess the level of Flaws and interpreting results.
• Complete LEVEL 1 and LEVEL 2 Fitness for Service assessment independently.
• Use a simulation Software to model problems and complete assessments.

Topics Covered

Day 1

• Introduction: The Idea and structure of the training. A full hands-on approach using real plant examples.
• The theory of Fitness for Service and how it applies to Fixed Equipment as a method for structural analysis.
• Structure of the Recommended Practice API 579-1/ASME FFS.
• The Roadmap of all sections and Parts and their relationship.
• How the defect morphology and the process application drives the appropriate level of assessments.
• Part 3 Assessment for Brittle Fracture Damage.
• Part 4 Assessment for General Metal Loss Damage.
• Part 5 Assessment for Localized Metal Loss Damage.
• Software approach. How to model problem on web-based software and interpreting results for screening.

Day 2

• Part 6 Assessment for Pitting Corrosion Damage.
• Part 7 Assessment for Blisters and HIC/SOHIC Damage.
• Part 8 Assessment Weld Misalignment and Shell Distortions Damage.
• LEVEL 1 & LEVEL 2 assessment examples and full stepwise procedure approach of the above.
• Software approach. Solve classroom problem using RAPIDSOLVE® FFS application.
• Provincial requirements and how an FFS assessment affects continued use of systems with known defects.

Day 3

• Part 9 Assessments for Crack-like Flaws.
• Part 10 Assessment for High Temperature Operations & Creep
• Part 11 Assessment for Fire Damage
• LEVEL 1 & LEVEL 2 assessment examples and full stepwise procedure approach of the above.
• Software approach. Solve classroom problem using RAPIDSOLVE® FFS application.
• Review of applications with multiple defects and dual part assessment requirements.

Day 4

• Part 12 Assessment for Dent, Gouge, and Dent Gouge Combinations Parts.
• Part 13 Assessment for Lamination defects.
• Part 14 Assessment for Fatigue defect.
• LEVEL 1 & LEVEL 2 assessment examples and full stepwise procedure approach of the above.
• LEVEL 3 Introduction and steps overview of API 579-1/ASME FFS with example: Pitting / Crack-like flaw.
• Software approach. Solve classroom problem using RAPIDSOLVE® FFS application.