API 579-1/ASME FFS-1 Fitness-For-Service Standard API CRE Meeting April 18, 2007 David A. Osage Chairman Joint API/ASME Fitness-For-Service Standards Committee 1

Presentation Overview Introduction Joint API/ASME Fitness-For-Service Standards Committee New Joint API and ASME FFS Standard Overview of API 579-1/ASME FFS-1 Balloting of API 579-1/ASME FFS-1 Technical Basis and Validation of API 579-1/ASME FFS-1 Relationships to Other FFS Standards What’s next 34

Introduction The first edition of API 579 produced by API CRE FFS Task Group is issued in 2000 and becomes the de facto international Fitness-For-Service (FFS) Standard for pressure containing equipment in the refining and petrochemical industries ASME forms Post Construction Committee (PCC) to develop standards for in-service fixed equipment FFS effort started under ASME PPC, existing API CRE Task Group continues to develop the next edition of API 579, many committee members are serving on both committees In order to streamline development efforts, pool resources, and promote widespread regulatory acceptance, API and ASME agree to form a joint committee to produce a single FFS standard that can be used for pressure-containing equipment for all industries

Joint API/ASME FFS Standards Committee Joint API/ASME Committee formed, first meeting takes place on February 5, 2002 Polices and procedures manual developed covering Charter Organization Officers Membership Meetings Committee Actions (Voting and Balloting) Public Review and Submittal to ANSI Interpretations Appeals Records Polices and procedures manual approved by API CRE and ASME BPTCS

Joint API/ASME FFS Standards Committee Oversight by API CRE and ASME BPTCS Membership Approval of standards actions Current committee has 39 members in 11 interest categories Regulatory/Jurisdictional Insurance/Inspection Petroleum Refining Petroleum Production Chemicals Manufacturing Pipeline Companies Power Generation Design/Engineering Repair/Manufacturing General Interest Pulp & Paper Membership includes international participation from France, UK, Japan, Canada, others…

New Joint API and ASME FFS Standard API 579 will form the basis of the new joint API/ASME standard that will be produced by the API/ASME joint committee The initial release of the new joint standard designated as API 579-1/ASME FFS-1 is scheduled for the second quarter of 2007 API 579-1/ASME FFS-1 2007 standard will include all topics currently contained in the first edition of API 579 and will also include new parts covering FFS assessment procedures that address unique damage mechanisms experienced by other industries API 579-1/ASME FFS-1 2007 will supersede API 579-2000

Overview of API 579-1/ASME FFS-1 Sections and Appendices in the API 579-2000 are being renamed to Parts and Annexes in API 579-1/ASME FFS-1 2007 New Enhancements – Existing Sections and New Parts Part 5 - Assessment of Local Thin Areas, assessment procedures for gouges have been 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 removed, assessment procedures for dents, gouges, and dent-gouge combinations have been 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 have been added Part 12 - Assessment of Dents, Gouges, and Dent-Gouge Combinations, new Part Part 13 - Assessment of Laminations, new Part

Overview of API 579-1/ASME FFS-1 New Enhancements – Existing and New Annexes Annex 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, Structural Stress/Master S-N Approach will be included Annex 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 Annex E - Compendium of Residual Stress Solutions, complete rewrite to incorporate new solutions developed by PVRC Joint Industry Project Annex F - Material Properties for a FFS Assessment, new stress-strain curve model incorporated Annex H - Technical Basis and Validation of FFS Procedures Annex K - Crack Opening Areas, new annex covering crack opening areas for through-wall flaws in cylinders and spheres

Overview of API 579-1/ASME FFS-1 Organization of Parts Part 1 – Introduction Part 2 – FFS Engineering Evaluation Procedure Part 3 – Assessment of Equipment for Brittle Fracture Part 4 – Assessment of General Metal Loss (tm < tmin - large area) Part 5 – Assessment of Localized Metal Loss (tm < tmin - small area) Part 6 – Assessment of Pitting Corrosion Part 7 – Assessment Of Hydrogen Blisters and Hydrogen Damage Associated with HIC and SOHIC Part 8 – Assessment of Weld Misalignment and Shell Distortions Part 9 – Assessment of Crack-Like Flaws Part 10 – Assessment of Equipment Operating in the Creep Regime Part 11 – Assessment of Fire Damage Part 12 – Assessment of Dents, Gouges, and Dent-Gouge Combinations Part 13 – Assessment of Laminations 47

Overview of API 579-1/ASME FFS-1 Organization of Annexes Annex A – Thickness, MAWP, and Stress Equations for a FFS Assessment Annex B – Stress Analysis Overview for a FFS Assessment Annex C – Compendium of Stress Intensity Factor Solutions Annex D – Compendium of Reference Stress Solutions Annex E – Residual Stresses in a FFS Evaluation Annex F – Material Properties for a FFS Assessment Annex G – Deterioration and Failure Modes Annex H – Validation Annex I – Glossary of Terms and Definitions Annex J – Currently Not Used Annex K – Crack Opening Areas 54

Balloting of API 579-1/ASME FFS-1 The initial ballot was issued on March 11th, 2002, and the final ballot was issued on March 28th, 2007 A total of 119 ballots were issued, closed, and all comments were resolved by the joint committee; an outstanding effort by all committee members! Two committees were simultaneously balloted, API/ASME Joint Committee on FFS and the API CRE Task Group on FFS, many members serve on both committees Worked with the following Joint Industry Projects to support balloting process; technology development is heavily leveraged MPC Fitness-For-Service JIP MPC HIC JIP MPC Project Omega JIP PVRC Div2 Re-write JIP PVRC Weld Residual Stress JIP Battelle Structural Stress JIP

Balloting of API 579-1/ASME FFS-1 Coordinated the balloting process of API 579-1/ASME FFS-1 with the new ASME Section VIII, Division 2 Pressure Vessel Code to achieve harmonization between Fitness-For-Service and design rules, where appropriate; feedback from both standards committees subsequently used to improve both documents Submitted for ANSI approval on February 23, 2007, final ANSI approval expected in May, 2007 (BSR8 & BSR9) ASME Board on pressure technology Codes and Standards (BPTCS) approved API 579-1/ASME FFS-1 on March 28, 2007 API CRE approval required, expected at the April 18, 2007 API Spring Meeting

Publication of API 579-1/ASME FFS-1 Editing performed by D.A. Osage on volunteer basis Streamlined publication process All parts produced in MS Word using MathType for equations, Visio for graphics, and SigmaPlot for graphs Production ready MS Word documents circulated to committee members during balloting process using MS Word red-line mode feature After final approval, MS Word versions of all Parts sent to E2G Publications Department for review with API Publications Staff and final document processing Hypertext Links added to MS Word files, PDF version produced with full hyperlink capability PDF version sent to API, forms basis of electronic version and paper version Very time/cost effective process for producing a large complex document (over 1700 pages) Production version of API 579-1/ASME FFS-1 currently posted on E2G website with DRAFT Watermark, available to committee members, password protected Waiting for final approval, publication expected in May 2007

Technical Basis and Validation of API 579-1/ASME FFS-1 Joint API/ASME FFS Committee committed to publishing the technical basis to all FFS assessment procedures utilized in API 579-1/ASME FFS-1 2007 in the public domain Appendix H of API 579-1/ASME FFS-1 2007 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 Publication of technical background has been instrumental in obtaining acceptance from regulatory bodies

Technical Basis and Validation of API 579-1/ASME FFS-1 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-For-Service Assessments (WRC 476) Master S-N Curve Method for Fatigue Evaluation of Welded Components (WRC 474) An Overview and Validation of The Fitness-For-Service Assessment Procedures for Locally Thin Areas in API 579 (WRC 505)

Technical Basis and Validation of API 579-1/ASME FFS-1 WRC Bulletins In Preparation An Overview of The Fitness-For-Service Assessment Procedures for Pitting Damage in API 579 Compendium of Temperature-Dependent Physical Properties for Pressure Vessel Materials (WRC 503) An Overview and validation of the Fitness-For-Service Rules for the Assessment of HIC/SOHIC 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 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

Relationships to Other FFS Standards Alternative FFS Methodologies from international standards permitted under a Level 3 Assessment; for example, Section 9 covering crack-like flaws provides reference to: Nuclear Electric R-6 Nuclear Electric R-5 (FFS in creep regime) BS 7910 (PD 6493) SAQ/FoU-Report 96/08 EPRI J-Integral Joint API/ASME Committee continuing to set up technical liaisons with other international FFS standard writing bodies Depending on committee review, next edition of API 579-1/ASME FFS-1 may reference FITNET FFS procedures

What’s Next API/ASME FFS Joint committee currently working on separate example problems manual, scheduled for release in 2008 Committee also addressing agenda items generated during balloting process Subgroup of committee working on FFS methods for cast iron rollers in the pulp & paper industry

What’s Next Technical advancements planned for the next release include Updated brittle fracture screening procedures Enhanced LTA assessment procedures Enhanced crack-like flaw assessment procedures Further improvements in residual stress solutions Improvements in material property evaluation for in-service components Assessment of HTHA (High Temperature Hydrogen Attack) Damage Assessment of Hot-Spot Assessment of Fatigue Damage Other needs based on user feedback

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