Fitness for Service (FFS) Assessments

Enhance the safety and performance of your essential equipment while minimizing repair and replacement needs. Element offer specialized services such as hydrogen pipeline assessments, generator retaining ring evaluations, and defect stability analyses, all adhering to international standards and enabling you to make data-driven choices. With Element's Fitness for Service assessments (FFS), you can determine the ongoing operation of your assets.

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What are Fitness for Service (FFS) Assessments at Element?

Fitness for Service assessments determine if equipment containing flaws, damage, or aging can safely continue operation when it no longer meets original construction codes. These assessments are critical for industries including Oil & Gas, Hydrogen, Power Generation, and Chemical Processing, where equipment integrity is essential for safe and efficient operations. At Element, we provide comprehensive FFS assessments following API 579-1/ASME FFS-1 international standards to evaluate the integrity of pressure-containing equipment. Our assessments analyze equipment condition during normal service to exceptional circumstances, delivering clear insights about your equipment's operational safety and reliability.

Materials testing scientist using microscope for quality analysis at Element laboratory

What Can Element Offer You for Fitness for Service (FFS) Assessments?

Components and materials we test

During Fitness For Service testing, Element can assess a comprehensive range of industrial equipment, including headers, drums, water/steam/gas piping, process piping, penstocks, turbine rotors and housing, pressure vessels, valves, furnaces, reactors, heat exchangers, and storage tanks. Our expertise extends to both new and aging infrastructure across multiple industries.

Key tests offered

Thermo-mechanical analysis under operating conditions

Structural analysis for anomaly detection

Defects propagation rate evaluation and stability assessment

Design verification and requalification

Faulted component assessment

Stability assessment for operating conditions

Methods and solutions offered

Our expert team employs advanced analytical methods including finite element analysis (FEA), fracture toughness testing, and metallographic analysis. For specialized applications, we utilize proprietary tools such as the Retaining Ring Module to assess defect propagation and incubation conditions in generator rotor retaining rings. We provide comprehensive evaluations using recognized procedures and standards like API 579, BS 7910, DNV, NE R5, and NE R6.

Which labs offer this service

Our team operates from energy hubs across the world, providing global access to our expert capabilities. Find out where your nearest energy hub is on our Locations Page.

Industry-leading expertise

Our experts are qualified to Level 2 and 3 for NDT and metallographic replicas, combining specialist knowledge in fracture toughness, finite element analysis, and fatigue testing to deliver comprehensive assessment solutions.

Standards we test to and components we test

These are our most prevalent requests. Don't see what you're looking for? Contact us!

API 579-1/ASME FFS-1
BS 7910
DNV
NE R5
NE R6

Your Challenges, Our Solutions

Equipment failure risks

We help prevent catastrophic failures through comprehensive structural and mechanical integrity assessments, providing clear insights into your equipment's operational safety and potential risk factors.

Uncertain equipment lifespan

Our advanced evaluation techniques determine remaining operational life, helping you make informed decisions about maintenance timing and resource allocation while ensuring safe, continuous operation.

Mitigating Risk in Complex environments

Complex environments such as nuclear and hydro power plants often involve challenging defect scenarios and harsh operating conditions. Element’s FFS assessments evaluate stability under these conditions to ensure long-term safety and reliability

Compliance with standards

Our assessments follow international standards like API 579-1/ASME FFS-1, ensuring your equipment meets all necessary compliance requirements while maintaining operational efficiency.

Why Choose Element

Element materials testing engineer operating precision measurement equipment for quality analysis

Comprehensive End-to-End Service

From initial evaluation to requalification and faulted component assessment, Element delivers thorough, lifecycle-long asset management.

Tailored Solutions for Complex Defects

Advanced assessments for brittle/ductile fracture, corrosion, erosion, and defect propagation—optimized for unique operating conditions.

Advanced technical qualification

Element’s experts hold Level 2 and 3 qualifications in NDT and metallographic replicas, specializing in FEA and fatigue testing.

Industry-leading standards compliance

We perform FFS assessments to API 579-1/ASME FFS-1 standards, ensuring compliance with globally recognized safety and integrity benchmarks.

Frequently asked questions

Can Element help with failure analysis and failure scenario evaluation?

Yes, Element assists with failure analysis by evaluating equipment conditions, defect propagation, and stability. We determine the plausibility of failure scenarios using recognized procedures and standards, helping you make informed decisions to prevent future issues.

How does Element evaluate hydrogen pipeline systems?

Element assesses the feasibility of using existing pipelines for hydrogen transportation by reviewing material certificates, operational data, and project documentation. We perform NDT replicas in the field and use standards like ASME B31.8, ASME B31.12, and EIGA IGC Doc 121/14 to evaluate safety and predictive component life.