API 579-2 / ASME PTB-14-2023 –

2nd Edition

Fitness-For-Service
Example Problems Manual

API/ASME Joint Fitness-For-Service Committee

 Fitness-For-Service Example Problems Manual – API 579-2 / ASME PTB-14-2023

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Copyright © 2024 by the American Petroleum Institute and The American Society of Mechanical Engineers

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FOREWORD
This publication supersedes API 579-2, 1st Edition/ASME FFS-2, which has been redesignated by ASME as
ASME PTB-14. It is provided to illustrate the calculations used in the assessment procedures in API 579-1/ASME
FFS-1 published in December 2021. API 579-1/ASME FFS-1 was written to be used in conjunction with industry’s
existing codes for pressure vessels, piping and aboveground storage tanks (e.g., API 510, API 570, API 653, and
NBBI NB 23 (NBIC)). The standardized Fitness-For-Service Assessment procedures presented in API 579-
1/ASME FFS-1 provide technically sound consensus approaches that ensure the safety of plant personnel and
the public while aging equipment continues to operate and can be used to optimize maintenance and operation
practices, maintain availability and enhance the long-term economic performance of plant equipment.

This publication is written as an API/ASME PTB technical publication. Its words shall and must indicate explicit
requirements that are essential for an assessment procedure to be correct. The word should indicates
recommendations that are good practice but not essential. The word may indicates recommendations that are
optional.

The API/ASME Joint Fitness-For-Service Committee intends to continuously improve this publication as changes
are made to API 579-1/ASME FFS-1. All users are encouraged to inform the committee if they discover areas in
which these procedures should be corrected, revised or expanded. Suggestions should be submitted to the
Secretary, API/ASME Fitness-For-Service Joint Committee, The American Society of Mechanical Engineers, Two
Park Avenue, New York, NY 10016, or [email protected] or to the Standards Department, API, 200
Massachusetts Avenue NW, Suite 1100, Washington, DC 20001, [email protected].

Items approved as errata to this edition are published on the ASME website under Committee Pages at
http://cstools.asme.org. Under Committee Pages, expand Board on Pressure Technology Codes & Standards
and select ASME/API Joint Committee on Fitness-For-Service. The errata are posted under Publication
Information.

This publication is under the jurisdiction of the ASME Board on Pressure Technology Codes and Standards and
the API Committee on Refinery Equipment and is the direct responsibility of the API/ASME Fitness-For-Service
Joint Committee.

Although every effort has been made to assure the accuracy and reliability of the information that is presented in
this standard, API and ASME make no representation, warranty, or guarantee in connection with this publication
and expressly disclaim any liability or responsibility for loss or damage resulting from its use or for the violation of
any regulation with which this publication may conflict.

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SPECIAL NOTES
This document addresses problems of a general nature. With respect to particular circumstances, local, state,
and federal laws and regulations should be reviewed.

Nothing contained in this document is to be construed as granting any right, by implication or otherwise, for the
manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything
contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

Neither API nor ASME nor any employees, subcontractors, consultants, committees, or other assignees of API or
ASME make any warranty or representation, either express or implied, with respect to the accuracy,
completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any
use, or the results of such use, of any information or process disclosed in this publication. Neither API nor ASME
nor any employees, subcontractors, consultants, or other assignees of API or ASME represent that use of this
publication would not infringe upon privately owned rights.

This document may be used by anyone desiring to do so. Every effort has been made by to assure the accuracy
and reliability of the data contained in them; however, API and ASME make no representation, warranty, or
guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss
or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication
may conflict.

This document is published to facilitate the broad availability of proven, sound engineering and operating
practices. This document is not intended to obviate the need for applying sound engineering judgment regarding
when and where this document should be utilized. The formulation and publication of this document is not
intended in any way to inhibit anyone from using any other practices.

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TABLE OF CONTENTS
Foreword ................................................................................................................................................... iii

Part 1 – Introduction
1.1 INTRODUCTION ...................................................................................................................................................... 1-1
1.2 SCOPE ................................................................................................................................................................... 1-1
1.3 ORGANIZATION AND USE ...................................................................................................................................... 1-1
1.4 REFERENCES......................................................................................................................................................... 1-1

Part 2 – Fitness-For-Service Engineering Assessment Procedure

2.1 GENERAL ............................................................................................................................................................... 2-1
2.2 CALCULATION PRECISION ..................................................................................................................................... 2-1
2.3 TABLES .................................................................................................................................................................. 2-2

Part 3 – Assessment of Existing Equipment for Brittle Fracture

3.1 EXAMPLE PROBLEM 1 ............................................................................................................................... 3-1
3.2 EXAMPLE PROBLEM 2 ............................................................................................................................... 3-3
3.3 EXAMPLE PROBLEM 3 ............................................................................................................................... 3-5
3.4 EXAMPLE PROBLEM 4 ............................................................................................................................... 3-7
3.5 EXAMPLE PROBLEM 5 .............................................................................................................................. 3-11
3.6 EXAMPLE PROBLEM 6 .............................................................................................................................. 3-13
3.7 EXAMPLE PROBLEM 7 .............................................................................................................................. 3-16
3.8 EXAMPLE PROBLEM 8 .............................................................................................................................. 3-19
3.9 EXAMPLE PROBLEM 9 .............................................................................................................................. 3-21
3.10 EXAMPLE PROBLEM 10 ............................................................................................................................ 3-22
3.11 EXAMPLE PROBLEM 11 ............................................................................................................................ 3-35
3.12 EXAMPLE PROBLEM 12 ............................................................................................................................ 3-37
3.13 EXAMPLE PROBLEM 13 ............................................................................................................................ 3-47
3.14 EXAMPLE PROBLEM 14 ............................................................................................................................ 3-49
3.15 EXAMPLE PROBLEM 15 ............................................................................................................................ 3-52
3.16 EXAMPLE PROBLEM 16 ............................................................................................................................ 3-55

Part 4 – Assessment of General Metal Loss

4.1 EXAMPLE PROBLEM 1 ............................................................................................................................... 4-1
4.2 EXAMPLE PROBLEM 2 ............................................................................................................................... 4-7
4.3 EXAMPLE PROBLEM 3 .............................................................................................................................. 4-12
4.4 EXAMPLE PROBLEM 4 .............................................................................................................................. 4-18
4.5 EXAMPLE PROBLEM 5 .............................................................................................................................. 4-27
4.6 EXAMPLE PROBLEM 6 .............................................................................................................................. 4-31
4.7 EXAMPLE PROBLEM 7 .............................................................................................................................. 4-35

Part 5 – Assessment of Local Thin Areas

5.1 EXAMPLE PROBLEM 1 ............................................................................................................................... 5-1
5.2 EXAMPLE PROBLEM 2 ............................................................................................................................... 5-7
5.3 EXAMPLE PROBLEM 3 .............................................................................................................................. 5-13
5.4 EXAMPLE PROBLEM 4 .............................................................................................................................. 5-28
5.5 EXAMPLE PROBLEM 5 .............................................................................................................................. 5-33
5.6 EXAMPLE PROBLEM 6 .............................................................................................................................. 5-38
5.7 EXAMPLE PROBLEM 7 .............................................................................................................................. 5-42

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5.8 EXAMPLE PROBLEM 8 .............................................................................................................................. 5-48

5.9 EXAMPLE PROBLEM 9 .............................................................................................................................. 5-52
5.10 EXAMPLE PROBLEM 10 ............................................................................................................................ 5-59
5.11 EXAMPLE PROBLEM 11 ............................................................................................................................ 5-74

Part 6 – Assessment of Pitting Corrosion

6.1 EXAMPLE PROBLEM 1 ............................................................................................................................... 6-1
6.2 EXAMPLE PROBLEM 2 ............................................................................................................................... 6-8
6.3 EXAMPLE PROBLEM 3 .............................................................................................................................. 6-14
6.4 EXAMPLE PROBLEM 4 .............................................................................................................................. 6-27
6.5 EXAMPLE PROBLEM 5 .............................................................................................................................. 6-38
6.6 EXAMPLE PROBLEM 6 .............................................................................................................................. 6-51

Part 7 – Assessment of Hydrogen Blisters and Hydrogen Damage Associated with HIC and SOHIC
7.1 EXAMPLE PROBLEM 1 ............................................................................................................................... 7-1
7.2 EXAMPLE PROBLEM 2 .............................................................................................................................. 7-12
7.3 EXAMPLE PROBLEM 3 .............................................................................................................................. 7-28
7.4 EXAMPLE PROBLEM 4 .............................................................................................................................. 7-33

Part 8 – Assessment of Weld Misalignment and Shell Distortions

8.1 EXAMPLE PROBLEM 1 ............................................................................................................................... 8-1
8.2 EXAMPLE PROBLEM 2 ............................................................................................................................... 8-4
8.3 EXAMPLE PROBLEM 3 .............................................................................................................................. 8-10
8.4 EXAMPLE PROBLEM 4 .............................................................................................................................. 8-12
8.5 EXAMPLE PROBLEM 5 .............................................................................................................................. 8-15
8.6 EXAMPLE PROBLEM 6 .............................................................................................................................. 8-22
8.7 EXAMPLE PROBLEM 7 .............................................................................................................................. 8-32

Part 9 – Assessment of Crack-Like Flaws

9.1 EXAMPLE PROBLEM 1 ........................................................................................................................................... 9-1
9.2 EXAMPLE PROBLEM 2 ........................................................................................................................................... 9-5
9.3 EXAMPLE PROBLEM 3 ........................................................................................................................................... 9-9
9.4 EXAMPLE PROBLEM 4 ......................................................................................................................................... 9-11
9.5 EXAMPLE PROBLEM 5 ......................................................................................................................................... 9-13
9.6 EXAMPLE PROBLEM 6 ......................................................................................................................................... 9-23
9.7 EXAMPLE PROBLEM 7 ......................................................................................................................................... 9-32
9.8 EXAMPLE PROBLEM 8 ......................................................................................................................................... 9-45
9.9 EXAMPLE PROBLEM 9 ......................................................................................................................................... 9-57
9.10 EXAMPLE PROBLEM 10 ....................................................................................................................................... 9-60
9.11 EXAMPLE PROBLEM 11 ....................................................................................................................................... 9-68
9.12 EXAMPLE PROBLEM 12 ....................................................................................................................................... 9-79

Part 10 – Assessment of Components Operating in the Creep Range

10.1 EXAMPLE PROBLEM 1 ......................................................................................................................................... 10-1
10.2 EXAMPLE PROBLEM 2 ......................................................................................................................................... 10-6
10.3 EXAMPLE PROBLEM 3 ....................................................................................................................................... 10-10
10.4 EXAMPLE PROBLEM 4 ....................................................................................................................................... 10-23
10.5 EXAMPLE PROBLEM 5 ....................................................................................................................................... 10-43

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Part 11 – Assessment of Fire Damage

11.1 EXAMPLE PROBLEM 1 .............................................................................................................................. 11-1
11.2 EXAMPLE PROBLEM 2 .............................................................................................................................. 11-3
11.3 EXAMPLE PROBLEM 3 .............................................................................................................................. 11-7
11.4 EXAMPLE PROBLEM 4 ............................................................................................................................ 11-31
11.5 EXAMPLE PROBLEM 5 ............................................................................................................................ 11-38
11.6 EXAMPLE PROBLEM 6 ............................................................................................................................ 11-44
11.7 EXAMPLE PROBLEM 7 ............................................................................................................................ 11-57
11.8 CHECK LIST EXAMPLE 1 ........................................................................................................................ 11-61
11.9 CHECK LIST EXAMPLE 2 ........................................................................................................................ 11-63

Part 12 – Assessment of Dents, Gouges, and Dent-Gouge Combinations

12.1 EXAMPLE PROBLEM 1 ......................................................................................................................................... 12-1
12.2 EXAMPLE PROBLEM 2 ......................................................................................................................................... 12-4
12.3 EXAMPLE PROBLEM 3 ......................................................................................................................................... 12-8
12.4 EXAMPLE PROBLEM 4 ....................................................................................................................................... 12-12
12.5 EXAMPLE PROBLEM 5 ....................................................................................................................................... 12-16

Part 13 – Assessment of Laminations

13.1 EXAMPLE PROBLEM 1 ......................................................................................................................................... 13-1
13.2 EXAMPLE PROBLEM 2 ......................................................................................................................................... 13-9

Part 14 – Assessment of Fatigue Damage

14.1 EXAMPLE PROBLEM 1 ......................................................................................................................................... 14-1
14.2 EXAMPLE PROBLEM 2 ......................................................................................................................................... 14-4
14.3 EXAMPLE PROBLEM 3 ....................................................................................................................................... 14-10
14.4 EXAMPLE PROBLEM 4 ....................................................................................................................................... 14-21
14.5 EXAMPLE PROBLEM 5 ....................................................................................................................................... 14-33
14.6 EXAMPLE PROBLEM 6 ....................................................................................................................................... 14-64
14.7 EXAMPLE PROBLEM 7 ....................................................................................................................................... 14-71

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PART 1

INTRODUCTION
PART CONTENTS

PART 1 ........................................................................................................................................................................ 1-1

1.1 INTRODUCTION ...................................................................................................................................................... 1-1
1.2 SCOPE ................................................................................................................................................................... 1-1
1.3 ORGANIZATION AND USE ...................................................................................................................................... 1-1
1.4 REFERENCES......................................................................................................................................................... 1-1

1.1 Introduction

Fitness-For-Service (𝐹𝐹𝑆) Assessments in API 579-1/ASME FFS-1 Fitness-For-Service are engineering

evaluations that are performed to demonstrate the structural integrity of an in-service component that may contain
a flaw or damage or that may be operating under specific conditions that could produce a failure. API 579-1/ASME
FFS-1 provides guidance for conducting 𝐹𝐹𝑆 Assessments using methodologies specifically prepared for
pressurized equipment. The guidelines provided in this standard may be used to make run-repair-replace
decisions to help determine if pressurized equipment containing flaws that have been identified by inspection can
continue to operate safely for some period of time. These 𝐹𝐹𝑆 Assessments of API 579-1/ASME FFS-1 are
currently recognized and referenced by the API Codes and Standards (510, 570, and 653), and by NB-23 as
suitable means for evaluating the structural integrity of pressure vessels, piping systems and storage tanks where
inspection has revealed degradation and flaws in the equipment or where operating conditions suggest that a risk
of failure may be present.

1.2 Scope

Example problems illustrating the use and calculations required for Fitness-For-Service Assessments described
in API 579-1/ASME FFS-1 are provided in this document. Example problems are provided for all calculation
procedures in both SI and US Customary units.

1.3 Organization and Use

An introduction to the example problems in this document is described in Part 2 of this Standard. The remaining
Parts of this document contain the example problems. The Parts in this document coincide with the Parts in API
579-1/ASME FFS-1. For example, example problems illustrating calculations for local thin areas are provided in
Part 5 of this document. This coincides with the assessment procedures for local thin areas contained in API 579-
1/ASME FFS-1, Part 5.

1.4 References

API 579-1/ASME FFS-1 Fitness-For-Service.

1-1