API 579 Training - Fitness For Service VIRTUAL TRAINING

Download Brochure

Upcoming Course

Code Start Date End Date Location Cost Instructor Register
PST0294-2020  12 Oct 2020  16 Oct 2020  VIRTUAL TRAINING  USD 2335  Mandar Mulay   Register

Past Course

Code Start Date End Date Location Cost Instructor Register
        Aaron A. Zick, Ph.D. 

Fitness-For-Service (FFS) assessments are quantitative engineering evaluations that are performed to demonstrate the structural integrity of an in-service component that may contain a flaw or damage. This training course is designed to give a detailed discussion of the subject of Fitness For Service concepts (FFS) with emphasis on the basic degradation mechanism and its consequences aspect.

It presents a thorough understanding of how the disciplines of material science, stress analysis, NDT and inspection practices can be applied for assessing the present structural integrity of the component, and deciding its fitness for continued service as well as the projected remaining life. This course covers the analytical methods and their applications are explained with numerous case studies. In order to suit the course to participants with or without a FFS background, the course will be delivered such a way that most of technical terms and both code statements and examples will clarify concepts.


 DAY- 1

  • Introduction to API 579
  • Fundamentals of Pressure vessels and piping
  • Review of Design formulas
  • Calculation of required thickness
  • Concept of MAWP
  • Scope and limitations of API 579
  • Definition of technical terms
  • FFS assessment procedures
  • Levels of assessments
  • Remaining strength factor
  • Failure assessment Diagrams
  • Reduced permissible MAWP
  • Remaining life assessment
  • Overview of flaw damage and assessment procedures.
  • Modes of deterioration and metal loss
  • Assessment for Brittle Fracture (Level 1)
  • Critical Exposure temperature (CET)
  • Minimum allowable temperature (MAT)

DAY- 2

  • Definition of general metal loss
  • Assessment general metal loss
  • Required data and measurements
  • Procedures for level1 assessment
  • Assessment techniques and acceptance criteria
  • Step-by step assessment method
  • Calculation of minimum required thickness
  • Calculation of average thickness
  • Coefficient of variation
  • Case studies and exercise on application of API 579 Methodology
  • Assessment of local metal loss.
  • Required data and measurements
  • Procedure for level 1 assessment

DAY- 3

  • Brief discussion on Pitting Corrosion
  • Step by step assessment method as per Level-1
  • Case study and Exercise
  • Assessment techniques and acceptance criteria for pitting
  • Assessment of Hydrogen damage - Hydrogen Induced Cracking
  • Assessment of Hydrogen blisters
  • Assessment techniques and acceptance criteria as per Level-1
  • Case study and Exercise
  • Assessment of weld Mis-alignments
  • Assessment of Shell distortion
  • Assessment techniques and acceptance criteria as per Level-1

DAY- 4

  • Assessment of Crack like flaws.
  • Assessment technique as per Level 1
  • Flaw Characterization- single cracks
  • Flaw Characterization- multiple cracks
  • Step by step assessment method
  • Failure assessment curves for crack-like flaws
  • Selection of FAD curves.
  • Maximum permissible crack dimensions.
  • Level-1 Assessment of cracks
  • Case study and Exercise on crack analysis as per Level-1
  • Assessment of creep damage
  • Creep range temperatures for various materials
  • Creep curves for various materials
  • Case studies on creep damage assessment

 DAY- 5

  • Assessment of fire damage
  • Deciding fire zones
  • Case studies on fire damage assessment
  •  Assessment of dents, gouges
  • Assessment techniques and acceptance criteria as per Level-1
  • Case studies on dents, gouges assessment
  • Assessment of Laminations
  • Case study on lamination assessment
  • Assessment of Fatigue Damage as per Level-1
  • Case study on fatigue damage
  • Final Review Exam (if required) 
  • Closing Session.
  • To familiarize participants with the main concepts and technical terms of degradation mechanisms.
  • To introduce participants to the concepts of FFS.
  • To explain to participants the basic concepts of degradation and FFS.
  • To provide participants with the basic technical and scientific knowledge for carrying out in depth inspection and engineering calculations.
  • To train participants to choose between ‘3 R’s i.e. Re-rate, Repair and Replace.
  • To introduce participants to different ways of evaluations and decision making as regards the repairs alterations and re-ratings
  • Assessment of future remaining life.

Pressure Vessel/ Piping/ Tank design engineers, process engineers, plant operating engineers and managers, Chemical/ mechanical engineers who are involved in integrity assessment of Columns, Vessels, tanks, piping etc. Also recommended for the Design engineers, Inspection persons and maintenance engineers involved in Repair, maintenance and trouble shooting of plant equipments in Refining, Petrochemical and Chemical industries. Individual certification of API 510/ 570/ 653 will be an added advantage to the participants

Each attendee must bring a Scientific Calculator

Aaron A. Zick, Ph.D.

Founder and President


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.


Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).


Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.



A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).