Oil and gas

Fitness for Service based on API579-1/ASME FFS-1-2007/2016

Synergi Plant

2017 public training course – 3 days

Who should attend?

The FFS course is designed for plant inspectors and engineers, NDT engineers, materials engineers and corrosion engineers who are responsible for managing the integrity of refinery and process plant equipment. For example, people working with pressure vessels, piping, storage tanks, heat exchangers, boilers and pipelines, either directly involved in a FFS assessment or indirectly involved such as reviewing of FFS work and data gathering for level 3 FFS projects.

Course content:

The 3‐day course materials are developed mainly based on the API 579-1/ASME FFS‐1 latest edition. The following topics are covered in the course:

  • Introduction to FFS 
  • General FFS assessment procedure
  • Screening assessment for brittle fracture
  • Assessment of general metal loss 
  • Assessment of local metal loss 
  • Assessment of pitting 
  • Assessment of weld misalignment and shell distortions 
  • Assessment of crack‐like flaws 
  • Integration with assessment procedures in BS 7910:2013 and R6 
  • Stress analysis.

The course seamlessly integrates other assessment codes such as BS 7910:2013 and R6. It also provides more than ten hands-on example problems where the students use dedicated software to run the analyses and one level 3 case studies with finite element analysis.

Course objectives:

The attendees of the course will be able to:

  • Perform and document level 1 and level 2 FFS assessment for brittle fracture, general metal loss, local metal loss, pitting, weld misalignment and shell distortions, crack-like flaws. 
  • Understand and review level 3 FFS analyses/reports 
  • Apply and review simple BS 7910 and R6 analysis 
  • Make decision for repair, replacement, and re-rate of equipment.

Lecturers

Dr. Jens P. Tronskar M.Sc., Ph.D., C.Eng, SenMWeldI, IWE, FSWS obtained his M.Sc. degree in Materials’ Physics and Physical Metallurgy from the Technical University of Norway (NTH) and was conferred Doctor of Philosophy (Ph.D.) in Applied Fracture Mechanics by the National University (NUS) of Singapore. His Ph.D. was on probabilistic fracture and fatigue of Floating Offshore Production and Storage vessels (FPSOs). Dr. Tronskar is a certified International Welding Engineer (IWE), a senior member of The Welding Institute and a UK-Engineering Council Chartered Engineer (C.Eng.). He was elected Fellow of Singapore Welding Society (FSWS) in April 2015. Currently he is holding a position as Senior Vice President and Chief Technology Officer at DNV GL’s Oil & Gas Technology Centre in Singapore. He has more than 35 years of experience of materials technology research, root cause and failure investigations, deterministic/probabilistic fracture mechanics analyses, and Fitness-For-Service analyses of structural, piping, process components and pipelines for offshore and onshore oil & gas and process industries. His experiences includes deterministic and probabilistic fracture mechanics, Fitness-For-Purpose and Engineering Critical Assessment of welds in C-Mn, CRA and CRA clad materials, Risk. Based Inspection (RBI) planning and life extension for refineries, petrochemical and gas plants/LNG. Dr. Tronskar has been involved in materials evaluation and testing for many North Sea offshore field development projects, onshore process plants and pipelines since the early 80s. He has been based in Asia and has been involved in similar work for offshore and onshore projects in South East Asia, China, South Korea, China, Australia, India and the Middle East and Afica. Dr. Tronskar has been a project sponsor and manager for a large number of pipeline ECA, FFS and repair projects. Dr Tronskar has introduced Risk Based Inspection and Asset Integrity Management for refineries, petrochemical and gas plants /LNG plants and terminals in SEA, ME and Asia. Dr. Tronskar has presented papers at international conferences in Europe, USA, Canada, South America, Australia and Asia. He has published more than 70 journal articles and peer reviewed conference papers on materials technology, welding and deterministic and probabilistic fracture mechanics and corrosion analyses.

Zhiyong Ou, B.Eng., PhD.Eng, joined the DNV GL Oil & Gas Technology Centre in Singapore in 2012 after obtaining a PhD in Engineering Mechanics from the National University of Singapore on the studies of fracture and fatigue of tubular joints. Zhiyong is responsible for more than 30 Engineering Critical Assessment (ECA) and Fitness-for-Service (FFS) projects for assessment and repair of onshore and offshore pipelines, oil & gas plants, offshore jacket structures, advanced FE simulations for cracks, corrosions mapping, subsea flanges and tees, and various structures. He has served as the project manager for more than 20 of these projects and he is quickly becoming known for his diligence and expertise with FFS and ECA in the oil & gas industry.

In-house training
We can also conduct a customized in-house training course and bring it to your place at your convenient time.

Who should attend?

The FFS course is designed for plant inspectors and engineers, NDT engineers, materials engineers and corrosion engineers who are responsible for managing the integrity of refinery and process plant equipment. For example, people working with pressure vessels, piping, storage tanks, heat exchangers, boilers and pipelines, either directly involved in a FFS assessment or indirectly involved such as reviewing of FFS work and data gathering for level 3 FFS projects.

Course content:

The 3‐day course materials are developed mainly based on the API 579-1/ASME FFS‐1 latest edition. The following topics are covered in the course:

  • Introduction to FFS 
  • General FFS assessment procedure
  • Screening assessment for brittle fracture
  • Assessment of general metal loss 
  • Assessment of local metal loss 
  • Assessment of pitting 
  • Assessment of weld misalignment and shell distortions 
  • Assessment of crack‐like flaws 
  • Integration with assessment procedures in BS 7910:2013 and R6 
  • Stress analysis.

The course seamlessly integrates other assessment codes such as BS 7910:2013 and R6. It also provides more than ten hands-on example problems where the students use dedicated software to run the analyses and one level 3 case studies with finite element analysis.

Course objectives:

The attendees of the course will be able to:

  • Perform and document level 1 and level 2 FFS assessment for brittle fracture, general metal loss, local metal loss, pitting, weld misalignment and shell distortions, crack-like flaws. 
  • Understand and review level 3 FFS analyses/reports 
  • Apply and review simple BS 7910 and R6 analysis 
  • Make decision for repair, replacement, and re-rate of equipment.

Lecturers

Dr. Jens P. Tronskar M.Sc., Ph.D., C.Eng, SenMWeldI, IWE, FSWS obtained his M.Sc. degree in Materials’ Physics and Physical Metallurgy from the Technical University of Norway (NTH) and was conferred Doctor of Philosophy (Ph.D.) in Applied Fracture Mechanics by the National University (NUS) of Singapore. His Ph.D. was on probabilistic fracture and fatigue of Floating Offshore Production and Storage vessels (FPSOs). Dr. Tronskar is a certified International Welding Engineer (IWE), a senior member of The Welding Institute and a UK-Engineering Council Chartered Engineer (C.Eng.). He was elected Fellow of Singapore Welding Society (FSWS) in April 2015. Currently he is holding a position as Senior Vice President and Chief Technology Officer at DNV GL’s Oil & Gas Technology Centre in Singapore. He has more than 35 years of experience of materials technology research, root cause and failure investigations, deterministic/probabilistic fracture mechanics analyses, and Fitness-For-Service analyses of structural, piping, process components and pipelines for offshore and onshore oil & gas and process industries. His experiences includes deterministic and probabilistic fracture mechanics, Fitness-For-Purpose and Engineering Critical Assessment of welds in C-Mn, CRA and CRA clad materials, Risk. Based Inspection (RBI) planning and life extension for refineries, petrochemical and gas plants/LNG. Dr. Tronskar has been involved in materials evaluation and testing for many North Sea offshore field development projects, onshore process plants and pipelines since the early 80s. He has been based in Asia and has been involved in similar work for offshore and onshore projects in South East Asia, China, South Korea, China, Australia, India and the Middle East and Afica. Dr. Tronskar has been a project sponsor and manager for a large number of pipeline ECA, FFS and repair projects. Dr Tronskar has introduced Risk Based Inspection and Asset Integrity Management for refineries, petrochemical and gas plants /LNG plants and terminals in SEA, ME and Asia. Dr. Tronskar has presented papers at international conferences in Europe, USA, Canada, South America, Australia and Asia. He has published more than 70 journal articles and peer reviewed conference papers on materials technology, welding and deterministic and probabilistic fracture mechanics and corrosion analyses.

Zhiyong Ou, B.Eng., PhD.Eng, joined the DNV GL Oil & Gas Technology Centre in Singapore in 2012 after obtaining a PhD in Engineering Mechanics from the National University of Singapore on the studies of fracture and fatigue of tubular joints. Zhiyong is responsible for more than 30 Engineering Critical Assessment (ECA) and Fitness-for-Service (FFS) projects for assessment and repair of onshore and offshore pipelines, oil & gas plants, offshore jacket structures, advanced FE simulations for cracks, corrosions mapping, subsea flanges and tees, and various structures. He has served as the project manager for more than 20 of these projects and he is quickly becoming known for his diligence and expertise with FFS and ECA in the oil & gas industry.

In-house training
We can also conduct a customized in-house training course and bring it to your place at your convenient time.

Course Agenda

Day 1
Subject
Subject
Introduction to FFS
Subject
General FFS assessment procedure
Subject
Screening assessment for brittle fracture
•    Hands-on problem solving
Subject
Assessment of general metal loss
•    Hands-on problem solving
Day 2
Subject
Subject
Assessment of local metal loss
•    Hands-on problem solving
Subject
Assessment of pitting
•    Hands-on problem solving
Subject
Assessment of weld misalignment and shell distortions
Day 3
Subject
Subject
Assessment of crack-like flaws with API 579, BS 7910:2013 and R6
•    Fracture mechanics fundamentals
•    Fracture mechanics testing
•    Fracture mechanics assessment for fracture limit
•    Fracture mechanics assessment for fatigue crack growth
•    Level 1 & 2 assessment of crack-like flaws in API 579
•    Level 3 assessment by API 579/BS 7910
•    Hands-on problem solving: Levels 2 & 3
Subject
Stress analysis and general level 3 assessment
•    Case study
Subject
Summary and conclusions
Subject
Quiz and feedback