API 579 - Fitness For Service

Mandar Mulay

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 to 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 an FFS background, the course will be delivered such a way that most of the technical terms and both code statements and examples will clarify concepts.



  • 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)


  • Definition of general metal loss
  • Assessment of 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 the application of API 579 Methodology
  • Assessment of local metal loss.
  • Required data and measurements
  • Procedure for Level 1 assessment


  • A 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


  • 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


  • 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.

What is API 579 training course objective?

  • 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.

Who should join API 579 training course by PetroSync?

Pressure Vessel/ Piping/ Tank design engineers, process engineers, plant operating engineers and managers, and Chemical/ mechanical engineers who are involved in the integrity assessment of Columns, Vessels, tanks, piping, etc. Also recommended for the Design engineers, Inspection persons, and maintenance engineers involved in the Repair, maintenance, and troubleshooting of plant equipment in the 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

Mandar Mulay

Mechanical Engineer

Mandar Mulay has about 20 years hands on experience in design and integrity assessment of Piping Systems, Reactors & Storage Tanks, Pressure Vessels, Power Boiler, and Heat Exchanger. He is well conversant with the major industry codes & standards such as ASME Sec. I, ASME B 31.1, B31.3 , B31.4 and B31.8, ASME Sec VIII, BS-5500, TEMA, API -650, IS 803, API 579, ASME PCC-2 etc.

Major projects closely associated with, in his professional career so far are, Qatar Chemicals, Shell, Castrol India, Reliance Industries, Cargill Foods USA, etc. His proficiency in Power Boiler, Piping and Pressure Vessel Codes enables him to trace the similarities and differences of these codes. He also actively involved as Instructor for programs on the subjects of ASME codes, Integrity Assessment, Fitness for Service, etc.

Along with his career in Engineering and Design Department in a multinational company at a very senior post for the last 20 years, he is also visiting faculty to a well known Engineering College in India for their P.G. Courses in Piping Design and Engineering

Apart from being visiting faculty, He has also conducted several Training Courses ( ASME Sec. I, ASME Sec. VIII, ASME B 31.3 Piping Codes , API 579 FFS code, ASME PCC-2 Repair practices, and Heat Exchanger Design Operations & Maintenance ) in Saudi Arabia, Qatar, Bahrain and UAE for engineers from companies like Saudi Aramco, SABIC group of Companies, Qatar Petroleum, ADNOC, BAPCO, DEWA, Gulf Petrochemicals etc. He has already conducted many times the training courses in API 579, where the participants rated him “Excellent” for these courses.

  • Code PST0294-202401
  • Start Date 05 Aug, 2024
  • End Date 09 Aug, 2024
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3250
  • Register
  • Code PST0294-202401
  • Start Date 02 Dec, 2024
  • End Date 06 Dec, 2024
  • Locations Bandung, Indonesia
  • Cost USD 3250
  • Register
  • Code PST0294-202301
  • Start Date 12 Jun, 2023
  • End Date 16 Jun, 2023
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3150
  • Code PST0294-202302
  • Start Date 11 Dec, 2023
  • End Date 15 Dec, 2023
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3150
  • Code PST0294-202303
  • Start Date 18 Dec, 2023
  • End Date 22 Dec, 2023
  • Locations Bandung, Indonesia
  • Cost USD 3150
Code Start Date End Date Locations Cost Instructor Register
PST0294-202401 05 Aug, 2024 09 Aug, 2024 Kuala Lumpur, Malaysia USD 3250 Mandar Mulay Register
PST0294-202401 02 Dec, 2024 06 Dec, 2024 Bandung, Indonesia USD 3250 Mandar Mulay Register
PST0294-202301 12 Jun, 2023 16 Jun, 2023 Kuala Lumpur, Malaysia USD 3150 Mandar Mulay
PST0294-202302 11 Dec, 2023 15 Dec, 2023 Kuala Lumpur, Malaysia USD 3150 Mandar Mulay
PST0294-202303 18 Dec, 2023 22 Dec, 2023 Bandung, Indonesia USD 3150 Mandar Mulay
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