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Failure Prevention and Repairs to Static Process Equipment & Piping

by Golden Masters for Training & Consultancy

Process equipment and piping systems constitute the major portion of plant assets and their integrity and reliability are essential for plant availability and performance.

AED 17000

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img Duration

5 days

Course Details

Course Description 
Process equipment and piping systems constitute the major portion of plant assets and their integrity and reliability are essential for plant availability and performance. 
Many process equipment and piping systems are subjected to hazardous service conditions and damage mechanisms which, if not adequately monitored and assessed, could result in major failures with consequential significant injuries and business losses.
It is essential to inspect the process equipment and piping system to detect any damage, characterize it, and assess its impact on the equipment integrity. With so many pieces of equipment and extensive piping systems and networks, it is obviously impossible to inspect totally every piece of equipment or piping in a plant. Therefore, an approach based on criticality, i.e. risk-based, taking into consideration the damage mechanisms and failure risk must be taken.
Course Objective:
The key objectives of this comprehensive course are as follows:
- To increase the participants awareness and understanding that the mechanical integrity of process equipment depends jointly on the proper design, operation, condition assessment, and maintenance of the equipment.
- To provide the participants with a clear understanding of the degradation mechanisms that process equipment could be subjected to over their operating life, how to identify them, predict and determine their impact, and what appropriate measures can be taken to prevent and control the resultant damage.
- To provide the participants with the knowledge and failure analysis skills they need to conduct damage and failure analysis so as to prevent similar failures from happening.
Course Certificate:
Masters Consultant certificate will be issued to all attendees completing minimum of 75% of the total tuition hours of the course.
Course Outline:
1.      DAY 1
– FAILURE MECHANICS   
1.1. WEAR & FAILURE MECHANISMS
1.1.1.     IMPERFECTIONS AND DEFECTS
1.1.2.     CORROSION MECHANISMS
1.2. FAILURE MODES
1.2.1.     FATIGUE
1.2.2.     FRETTING
1.2.3.     CREEP & THERMAL FATIGUE,
1.2.4.     STRESS CORROSION CRACKING, OTHER MODES
1.3. MATERIAL PROPERTIES, AND SELECTION
1.3.1.     CARBON & ALLOY STEELS
1.3.2.     NICKEL, TITANIUM, AND SPECIALTY ALLOYS.
1.3.3.     ALUMINUM, ALUMINUM ALLOYS.
1.3.4.     COPPER, COPPER ALLOYS.
1.3.5.     PLASTIC PIPING.
1.3.6.     ALTERNATIVE OPTIONS-LININGS, CLADDING.
1.3.7.     LIMITATIONS AND SAFEGUARDS.
1.3.8.     MATERIAL SELECTION - ECONOMICS-LIFE CYCLE COSTING.
2.      DAY 2 
- FAILURE PREVENTION BY DESIGN
2.1. FAILURE CAUSES – DESIGN, OPERATION; MAINTENANCE, OTHER CAUSES
2.2. MATERIAL PROPERTIES, AND SELECTION.
2.2.1.     PHYSICAL PROPERTIES AND LIMITATIONS OF  COMPONENTS
2.2.2.     PHYSICAL PROPERTIES OF STEEL AND ALLOY PIPING AND TUBING
2.2.3.     PHYSICAL PROPERTIES OF FITTINGS
2.3. BASIC DESIGN
2.3.1.     PRESSURE VESSELS
2.3.2.     PIPING SYSTEMS
2.3.3.     LIQUID STORAGE TANKS
2.4. OPERATION AND MAINTENANCE OF PROCESS EQUIPMENT
2.5. DAMAGE MECHANISMS AFFECTING PROCESS EQUIPMENT
3.      DAY 3
- PROCESS EQUIPMENT FAILURES 
3.1. FAILURES IN PRESSURE VESSELS, PIPING AND BOILERS
3.1.1.     STRENGTH REDUCTION THROUGH MATERIAL LOSS
3.1.2.     CASE HISTORIES
3.2. PIPING SYSTEM VIBRATION
3.2.1.     MECHANICAL & FLOW INDUCED RESONANCE
3.2.2.     TRANSIENT HYDRAULIC PULSATION
3.2.3.     PIPE SUPPORTS AND RESTRAINTS
3.2.4.     WIND LOADING
3.3. INDUSTRY PRACTICES FOR FAILURE PREVENTION
4.      DAY 4 
– INSPECTION, ASSESSMENT AND MAINTENANCE
4.1. INSPECTION STRATEGIES PLANS AND PROCEDURES – RISK BASED INSPECTION (API 580)
4.1.1.     DEVELOPING AN RBI PLAN.
4.1.2.     FITNESS-FOR-SERVICE ASSESSMENT (API 579).
4.2. NDT METHODS AND TECHNIQUES.
4.2.1.     PROBABILITY OF DETECTION.
4.2.2.     DAMAGE CHARACTERIZATION.
4.2.3.     SELECTING THE CORRECT TECHNIQUE(S).
4.3. PIGGING OF PIPELINES.
4.3.1.     SMART PIGGING.
4.3.2.     CLEANING.
4.3.3.     OPERATIONAL PROCEDURES.
5.      DAY 5 
– OPERATION AND MAINTENANCE
5.1. MAINTENANCE PROGRAMS
5.2. REPAIR AND ALTERATION OF PRESSURE EQUIPMENT AND PIPING
5.2.1.     RERATING PIPING AND PRESSURE VESSELS.
5.2.2.     ESTIMATION OF CONSEQUENCES OF PRESSURE VESSELS AND PIPING FAILURES.
5.3. FAILURE ANALYSIS TECHNIQUES.

Masters Training Company was established in response to the growing need for quality training to support the business community within your Company, Department or Organization by providing a high standard of Training Programs, Courses, Seminars, Workshops and Consultancy Services to employees in a very competitive business environment. 

 
Following the latest trends and ideas in Technology and Management techniques, and with its in-depth knowledge of the business environment, Masters Training Company is able to meet the special requirements of both local and international business throughout the Middle East. Masters Training & Consulting is an independent multinational firm with more than 25 years of experience in helping regional organizations develop their human capital in all fields of management. 
 
Since 1990, we have been entrusted by our clients to provide the most reliable training and consulting products and services in the region. Our innovative and diversified range of training programs and consulting services are designed and delivered by an ever-growing team of full time multilingual consultants experienced in providing solutions relevant to this part of the world and applicable to today’s business challenges.
 
We pride ourselves on our track record in this regard and on our long-standing relationships with our clients, many of whom have been with us since we started business. 
 
 
Our public training programs have attracted more than 300,000 participants from almost 3,000 organizations many of whom also entrust us with their needs for bespoke in-company programs. Our client base is steadily growing and so is our commitment to remain the regional leaders in the fields of training and consulting.

Masters is also an approved vendor from KHDA & ILM

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  • Sheikh Zayed Road Branch

    Kherbash Tower, Office # 1803 & 1804, Sheikh Zayed Road, Dubai

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