Pressure Vessels, Tanks and Piping Systems

Pressure Vessels, Tanks and Piping Systems

OBJECTIVES

• Latest techniques to determine the fitness-for-service of operating tanks, vessels, piping systems and pipelines; and make cost-effective run-repair-replace decisions based on the principles of API recommended practice 579 “Fitness-for-Service”
• Balanced approach between the fundamental technical principles of structural integrity, stress and fracture analysis, and their practical application to field conditions
• Provides the participants with the tools necessary to recognize and assess defects in pressure vessels, storage tanks and piping
• Presents and applies the fundamentals rules of the ASME code to operating equipment and systems
• Introduces the participants to the practical application of the ASME and API rules for structural integrity of static equipment and pipelines, and their use to assess remaining life
• Applies API/ASME 579 “Fitness-for-Service” through practical examples to analyze degraded conditions and make cost-effective repair or use-as-is decisions
• Applies the step-by-step 3-level approach of API/ASME 579 to evaluate inspection results and recognize potential failure modes
• Technical basis for reliability-based (risk-based) evaluation of remaining life
• Latest developments in defect assessment techniques, starting with simple rules (level 1) and progressing to the more comprehensive evaluation techniques (level3)
• Participants will be able to evaluate the structural integrity of corroded or damaged equipment, and assess their remaining life. Degradation mechanisms include: brittle fracture, general metal loss, local wall thinning, pitting, blisters and laminations, mechanical defects (dents, gouges, misalignment, and distortion), crack-like flaws (stress corrosion cracking, weld flaws, crack-like defects), fatigue, and fire damage

WHO SHOULD ATTEND?

This training program is intended for technical professionals, supervisors and managers responsible for ensuring the integrity and cost-effective operation of in-service pressure equipment, storage tanks, piping and pipelines throughout their life cycle including design, operation, and maintenance in the petroleum, petrochemical, process and power industries:

• Plant engineers and designers, corrosion and materials engineers, project engineers
• Reliability and integrity supervisors and engineers including safeguarding/MOC engineers
• Inspection engineers and inspectors responsible for monitoring and assessing the condition of pressure equipment and piping systems
• Maintenance and operations supervisors and engineers responsible for shutdown planning and implementation, maintenance and repairs/alterations of pressure vessels, heat exchangers, storage tanks, piping and pipelines

COURSE OUTLINE

Foundations of Fitness-For-Service Assessment

• Introduction
• Overview of API codes and standards
• Overview of ASME codes and standards with historical background
• Overview of Mechanical Integrity of Pressure Vessels & Piping System
• Fitness For Service
• Overview of API 579 contents, objectives and applications
• How to apply API 579 for cost-effective run-or-repair decisions
• Fitness-for-Service assessment procedure
• An overview of what is new in the latest release
• Structure and Contents of the FFS Standard
• List of Parts and Annexes and examples of major Parts
• PART 1 – Introduction
• PART 2 – Fitness-For-Service Engineering Assessment Procedure

Background of Stress Calculations for FSS Assessment

• ANNEX A – Thickness, MAWP & Stress Equations for a FFS Assessment
• Calculation of tmin, MAWP (MFH) & Membrane Stress
• Pressure Vessel & Boiler Components: Shells, Heads, Nozzles
• Piping components & Boiler Tubes
• Storage Tanks
• ANNEX G – Damage Mechanisms
• Deterioration and Failure Modes
• Pre-Service and In-Service Deficiencies
• NDE (NDT) Techniques
• PT, VT, MT, ET, UT, RT
• PART 3 – Assessment of Existing Equipment for Brittle Fracture
• Overview of Brittle Fracture Mechanism
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation

Metal Loss, Corrosion, Pitting and Blisters

• PART 4 – Assessment of General Metal Loss
• Overview of Corrosion Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• PART 5 – Assessment of Local Metal Loss
• Overview of Local Metal Loss Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• PART 6 – Assessment of Pitting Corrosion
• Overview of Pitting Corrosion Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• PART 7 – Hydrogen Blisters, HIC & SOHIC
• Overview of Hydrogen Damage
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation

Local Damage, Cracks, Creep

• PART 8 – Weld Misalignment & Shell Distortions
• Overview of Weld Misalignment & Shell Distortions
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• PART 9 – Assessment of Crack-Like Flaws
• Overview of Fracture Mechanics
• Elements of RSTRENG
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example
• PART 10 – Assessment of Components Operating in the Creep Range
• Overview of Creep Damage Mechanisms
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Worked example

Fire and Mechanical Damage

• PART 11 – Assessment of Fire Damage
• Overview of Fire Damage
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Case study – Example of fire damage assessment
• PART 12 – Assessment of Dents, Gouges, and Dent-Gouge Combinations
• Overview of Mechanical Damage
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• PART 13 – Assessment of Laminations
• Overview of Laminations and their Role
• Data Requirements
• Assessment Techniques and Acceptance Criteria (Levels 1-3)
• Remaining Life Assessment and Remediation
• Software review
• Various software packages considered for FFS
• Overview and Wrap Up