Course details

Overview ?

Why Choose this Course?

This course is designed to provide practical aspects of the mechanical design of pressure vessels, storage tanks, thermal equipment, piping systems and fluid transport machinery. The course will discuss the performance of these components under various operating conditions including in-depth explanation on the process of material degradation such as corrosion, erosion, fatigue and others that may lead to component failure.

Several examples and case studies included in the workshops and will demonstrate the application of Fitness for Service (FFS) assessment method that enables quantitative evaluation of the remaining life in service of any component of equipment. Failure prevention methods will also be discussed and explained.

The course will feature:

Explanation of mechanical design of pressurized equipment according to ASME Code
Consideration of best operating conditions: Integrity Operating Window and MOC
Analysis of damage and degradation mechanisms that affect process equipment and piping
Guidance for selecting the most appropriate inspection method based on API code guidelines
Procedure for assessing the existing flaws and defects in the given component

What are the Goals?

By the end of this course, participants will be able to:

Understand the safe design and operation of pressurized process equipment
Follow the procedure for inspection and testing of process equipment
Apply the fundamental concepts and strategies to prevent failures
Use the best practices of FFS to estimate the remaining life of operating equipment
Select the methods of repair and alteration of pressurized process equipment

Who is this Course for?

This course is designed to benefit all levels of Technical Personnel in the oil and gas industry as well as in chemical and process industries but will greatly benefit:

Process, Mechanical and Chemical Engineers
Operation and Maintenance Engineers
Project Engineers
Supervisors and Managers
Technical Personnel involved in inspection

How will this be Presented?

This course will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension and retention of the information presented. This includes formal lectures and interactive worked examples with active contribution of all delegates during discussions and team work. Real life examples (i.e. case studies) will be selected to illustrate the procedure for carrying out typical equipment failure analysis.

The emphasis in the entire course will be on the explanation of equipment failure causes and safety operation system as well as providing answers to problems that is encountered in everyday practice. There will be ample opportunities for open discussion and sharing professional experiences on existing and new technologies.

The Course Content

Day One

Overview of Design Features of Process Equipment and Piping System

General Concept of Safety in Design: Codes and Standards
Design Features of Pressure Vessels and Storage Tanks
Design Features of Piping Systems
Design Characteristics of Fluid Handling Equipment
Design Characteristics of Thermal Equipment
Overpressure Protection of Equipment

Day Two

Overview of Operation Issues of Components of Process Equipment

Safe Operation of Process Equipment: Integrity Operating Window
Over-pressuring of Process Equipment
Uncontrolled Runaway Chemical Reaction
Overheating of Boiler Tubes
Abnormal Operation of Fluid Handling Equipment
Vibration of Piping Systems

Day Three

Failure Modes and Fracture Mechanisms

Characteristics of Material Used for Construction of Process Equipment
Material Degradation Processes
Causes of Failures of Process Equipment and Piping Systems
Failure Modes
Fracture Mechanisms
Lessons Learnt from Major World Equipment Failures

Day Four

Design and Operation of Fluid Handling Equipment

Condition Monitoring
Inspection and Testing Techniques: API 572, API 510, API 570
Risk Based Inspection (RBI): API 580
Fitness for Service Assessment: API 579/ASME FS1
Failure Evaluation and Calculation of Component Remaining Life
Failure Prevention Methods

Day Five

Repairs, Alterations and Rerating of Process Equipment

Classification of Repairs
Repair Best Practices for Pressure Vessels and Other Equipment
Rerating of Pressure Vessels
Hot Taping and Line Stopping

Positive Material Identification (PMI)

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Day 4

Day 5

Training Methodology

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