Integrity Despite Defects Podcast on FFS
- Rohit Bafna
- Jun 28
- 3 min read
TCR Advanced Engineering recently released an insightful and technical podcast titled “Integrity Despite Defects – Fitness for Service”, featuring Mr. Paresh Haribhakti, Managing Director, and Mr. Ketankumar Upadhyaya, General Manager (Reliability Engineering). The podcast, now available on YouTube, offers a deep dive into Fitness for Service (FFS) assessments, their practical application, benefits, and limitations across various industries.
🎧 Watch the full podcast here: https://youtu.be/fl8KpvroRzI?si=O85vWEF63gaFDXIs
Why Fitness for Service (FFS) Matters
In the podcast, the speakers highlight the importance of API 579 / ASME FFS-1 standards in determining whether equipment with existing defects can continue to operate safely. As emphasized by Mr. Haribhakti, FFS allows industries to “live with the defects”—when they are properly analyzed and deemed non-critical—rather than opting for premature, costly repairs or replacements.
TCR Advanced plays a pivotal role in conducting FFS assessments, helping industries reduce downtime, ensure safety, and extend the life of aging plant equipment without compromising performance or integrity.
Key Insights from the Podcast:
✅ Multidisciplinary Approach
FFS is not just about engineering; it’s a synergy of metallurgy, process knowledge, mechanical design, and non-destructive evaluation (NDE). The speakers stress the importance of collaboration between chemical engineers, metallurgists, design experts, and NDT specialists.
✅ Evolving Codes and Standards
From the inception of API 579 in 2000 to the collaborative versions with ASME (FFS-1), the standards have become comprehensive. The discussion also touches on BS 7910, which TCR uses for Level 2 fracture mechanics-based assessments, particularly for flaw acceptance and crack analysis.
✅ Real-Life Case Studies
Mr. Roy recounts historic examples from his career—analyzing dented vessels and weld defects before FFS codes existed—demonstrating how principles similar to today’s standards have stood the test of time.
✅ Limitations of FFS
The podcast is honest about where FFS has boundaries. High-Temperature Hydrogen Attack (HTHA) and Stress Corrosion Cracking (SCC) remain difficult to quantify due to unknown crack propagation rates or subtle damage mechanisms.
TCR’s Proven FFS Methodology
TCR Advanced provides comprehensive FFS assessments in line with API 579, ASME FFS-1, and BS 7910 Level 2 standards. From nuclear pressure vessels to high-risk items in the refining and construction industries, our fracture mechanics methodologies have global credibility.
TCR's FFS Framework Includes:
NDE & Defect Sizing
Material Property Evaluation
Past & Future Operating Condition Review
Stress Analysis (including Finite Element Analysis – FEA)
Damage Mechanism Identification (e.g., HIC, fatigue, creep)
Common Triggers for FFS Assessments:
Discovery of flaws like cracks or local thinning
Changes in operating conditions
Failure to meet updated design codes
Benefits of Fitness for Service Assessment
✔ Extend Equipment Life Without Compromise
✔ Avoid Costly Repairs or Replacements
✔ Ensure Safe and Reliable Operation
✔ Plan Better Inspection Intervals
✔ Make Informed “Run, Repair, Replace” Decisions
Learn with TCR: Integrity Despite Defects
TCR Advanced has also launched a dedicated training program on FFS titled “Integrity Despite Defects”, covering the fundamentals of defect evaluation, API/ASME standards, and hands-on case discussions. This is a must-attend for inspection, design, welding, and operations engineers.
📩 Get in touch to learn more about our training, consulting, and assessment services in FFS.📞 Contact us via www.tcradvanced.com
🎥 Don’t miss the podcast that’s already making waves in the reliability and integrity community.
Watch Now – and share it with your colleagues who care about plant safety, uptime, and smart asset management.
