Corrosion Assessment & Fitness-for-Service (Level 3 using Abaqus)
Course Overview
As industries face increasing challenges with ageing assets, corrosion remains the leading cause of pressure equipment failures and unplanned shutdowns. This course offers a rare opportunity to gain practical, advanced skills in Level 3 Fitness-for-Service (FFS) corrosion assessment using Abaqus, bridging the gap between inspection data, API 579 requirements, and real-world engineering decisions.
This intensive 5-day training program equips engineers and integrity specialists with the advanced knowledge and practical skills required to perform corrosion and Fitness-for-Service (FFS) assessments in line with API 579/ASME FFS-1. The course bridges fundamental concepts with advanced finite element analysis (FEA) using Abaqus, enabling participants to assess metal loss, simulate damage mechanisms, and make confident decisions regarding the continued operation of pressurised components.
Through a combination of lectures, worked examples, and hands-on Abaqus workshops, participants will develop expertise in Level 1, Level 2, and full Level 3 corrosion assessments.
This course is not just about theory, it’s about applying advanced analysis tools to real integrity challenges and making informed, defensible engineering recommendations.
Why Attend?
- Upgrade your expertise beyond Level 1 & 2 assessments to confidently perform full Level 3 FFS evaluations.
- Gain hands-on FEA skills in Abaqus specifically applied to corrosion and metal loss problems.
- Enhance your decision-making ability on repair, replacement, or continued service of pressurised components.
- Position yourself as a specialist in Fitness-for-Service, a skill highly sought after in oil & gas, power, and petrochemical sectors.
Learning Outcomes
By the end of this training course, participants will be able to:
- Interpret and apply the API 579 framework for corrosion and metal loss damage assessment.
- Carry out Level 1 and Level 2 screening using RSF, MAWP, and thickness equations.
- Build and validate FEA models in Abaqus for Level 3 assessments of corroded pressure equipment.
- Evaluate realistic degradation scenarios including wall thinning, localized pitting, and geometric irregularities.
- Integrate inspection data into simulation workflows for decision-making on repair vs. continued service.
Daily Course Content
Day 1 – Fitness-for-Service Fundamentals
- API 579/ASME FFS-1 overview: structure, objectives, and applications
- The Eight-Step FFS Assessment Procedure
- Design and construction principles for pressure equipment
- Annex C: thickness, MAWP, and stress equations
- Common fabrication defects and in-service degradation mechanisms
Day 2 – Corrosion Assessment (Level 1 & 2)
- Identifying general vs. localized corrosion
- Thickness measurement methods and inspection best practices
- Calculating RSF and MAWP for corroded components
- Screening criteria and decision-making trees
- Recognising limitations of Level 2 and transition to Level 3
Day 3 – Abaqus Fundamentals for FFS
- Introduction to Abaqus environment and FFS applications
- Geometry creation for corroded profiles
- Material property definitions for degraded structures
- Meshing strategies for corrosion and metal loss regions
Day 4 – Advanced Abaqus Modelling
- Nonlinear analysis of corroded components
- Simulating wall thinning, localized pits, and irregular geometries
- Boundary conditions and load cases for realistic operation
- Case studies of degraded pressure equipment
Day 5 – Full Level 3 FFS Workflow
- Integrating inspection datasets into Abaqus models
- Performing full Level 3 corrosion assessment per API 579
- Repair vs. continued service decision-making
- Documentation and reporting for integrity and reliability teams
Who Should Attend
This course is designed for: Mechanical, materials, and integrity engineers working in oil & gas, petrochemical, power, and manufacturing industries.
- Asset managers and inspection specialists responsible for pressure vessels, tanks, and pipelines.
- Professionals seeking advanced skills in Fitness-for-Service, FEA modelling, and API 579 compliance.
- Researchers and consultants interested in the integration of structural integrity and simulation tools.
A basic understanding of corrosion principles and oil and gas operations is helpful, but not essential. Fundamental concepts will be covered during the course.
Included Materials
- Downloadable course slides (PDF)
- Worked examples from API 579, BS 7910, and ASME B31.G using Abaqus and hand calculations
- Supplementary fracture mechanics refresher notes
Delivered by Specialists
The course is delivered by experienced practitioners in structural integrity, fracture mechanics, and Fitness-for-Service (FFS), combining academic research expertise in fracture and fatigue of structural materials with extensive industry project experience across oil & gas, refining, petrochemicals, and power generation. With consultancy backgrounds in FFS, Engineering Critical Assessments (ECA), and integrity management, the instructors ensure the training is applied, practical, and immediately relevant to professional practice, equipping participants to confidently apply advanced FEA in Abaqus to real industry challenges
Key Benefits
- Gain hands-on experience with Abaqus for corrosion assessment.
- Learn directly from industry practitioners with expertise in FFS and FEA.
- Understand the limitations of Level 1 and 2 assessments and confidently perform Level 3 analysis.
- Acquire skills that are directly applicable to real-life integrity management and RBI planning.
- Receive a Certificate of Completion recognised for professional development
Ready to master Corrosion Assessment & Fitness-for-Service (Level 3 using Abaqus)?
Click the button below to book your training session today and become an expert in corrosion management and asset integrity systems for oil and gas operations.