Fitness-for-Service (FFS) Archives - The Equity Engineering Group, Inc.

Reformer MOV Cracking FFS Case Study

Oct 25, 2024

This case study explores fatigue cracking in motor-operated valves (MOVs) used to cycle flow in and out of reformer unit reactors. Surface flaws were discovered during a recent turnaround which prompted further investigation. As only a few of the MOVs were opened and inspected, the owner-user was concerned about the extent and severity of cracks in additional valves. In this article, the authors share the details of the case study and how Equity’s recommendations helped the client make informed repair decisions.

Are Dents Really a Problem?

Sep 24, 2024

Pipelines are susceptible to dents. There are currently several assessment procedures available for evaluating this damage mechanism and determining whether a dent poses a viable threat to the integrity of a component. In this article, Kevin and Daniel discuss common analysis methods for the critical failure mechanisms, potential failure mechanisms such as creep, complex dent configurations, and highlight the value of using a Level 3 finite element analysis (FEA) to determine whether the dent is truly a problem.

Managing Refractory Degradation and Hotspots in Cold-Walled Equipment

Aug 26, 2024

Refractory linings are used to protect pressure vessels and piping components from hot process conditions but can degrade over time, leading to hotspots, creep damage, and potential failure. In this article, the authors discuss the benefits of conducting periodic inspection programs to manage refractory degradation and share an example to highlight the importance of detecting permanent material damage caused by creep or creep-fatigue.

Advancements in Risk-Based Inspection Strategies for Ammonia Storage Tanks

Apr 30, 2024

Developing a repeatable, in-service inspection strategy for ammonia storage tanks is difficult; however, it will help improve operational reliability and minimize the probability of failure from several damage mechanisms, including ammonia stress corrosion cracking (SCC). In this article, the authors discuss Equity’s multi-disciplinary approach to navigate the challenges of these high-consequence ammonia storage tanks. Read how we integrate risk-based inspection (RBI), fitness-for-service (FFS), and materials and corrosion expertise to provide a comprehensive and practical inspection strategy.

PSA on PSA Reliability

Mar 26, 2024

Learn how pressure swing adsorbers (PSAs) are crucial yet challenging in gas separation, and how a comprehensive lifecycle management plan based on engineering and fitness-for-service (FFS) can enhance reliability and extend equipment life. In this article, Neal and Kate discuss the importance of remaining life and inspection optimization studies in managing severe cyclic fatigue service, highlighting how pre-emptive fatigue studies guide inspection plans for PSA vessels. You will learn about inspection strategies and how to maximize capital investments through engineering strategies.

Fitness-for-Service for Asset Management of Air Coolers

Sep 25, 2023

Air-cooled heat exchangers (ACHEs) are designed to use ambient air to cool or condense a process fluid, which eliminates the need for large cooling water capacities. In this article, Kate and Ben discuss how a fitness-for-service (FFS) assessment can be a very powerful tool in air cooler lifecycle management to improve inspection planning and guide run, repair, or replace decisions.

Leveraging Advanced Analysis for Coke Drum Reliability

May 30, 2023

Coke drums in delayed coker units present many reliability problems because they are subjected to unique types of damage mechanisms due to their operation. Thermal fatigue cracking is common in regions of high thermal stress due to frequent and severe thermal cycling. Bulging is also common because of this severe thermal cycling that creates hot and cold spots due to channeling effects in the coke formation that results in thermal ratcheting or progressive cyclic plastic strain accumulation.

Fundamentals of Design by Analysis

May 30, 2023

Combining design by analysis (DBA) methods with modern computational approaches provides critical engineering tools for evaluating the structural integrity of in-service equipment and new equipment designs. To know which DBA technique to employ, it is essential to understand all possible failure modes based on equipment operation and loading scenarios. In this article, Phillip offers a high-level overview of modern DBA techniques and procedures for providing protection against plastic collapse, local failure, buckling, and cyclic failure.

Proactive FFS for Volumetric Damage

Jan 31, 2023

Performing a proactive FFS assessment on equipment with volumetric wall loss can save both time and money during a turnaround. You can minimize inspection scope and outline a set of well-defined ‘goal posts’ for determining acceptability and identifying a targeted inspection list. In this article, the authors share multiple tips to proactively assess volumetric damage as it relates to the requirements of API 579-1/ASME FFS-1, Part 4 and Part 5.

Proactive FFS: Advantages of Brittle Fracture Screening on Piping and Vessels

Jan 31, 2023

Proactively conducting brittle fracture assessments on higher-risk pressure equipment and piping, even if it was built relatively recently, will help prevent unexpected failures. This article identifies the three components that drive susceptibility to brittle fracture and includes two case studies to help demonstrate the benefits of using a fracture mechanics-based approach.

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