Process Equipment & Piping: Failures, Failure Prevention and Repairs

Process Equipment & Piping: Failures, Failure Prevention and Repairs

OBJECTIVES

• 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.

WHO SHOULD ATTEND?

Maintenance, production and other plant engineers responsible for process equipment.

New graduates will gain essential and integrated knowledge about pressure equipment and piping systems design and the significance of appropriate design, operation and maintenance on their mechanical integrity. 

COURSE OUTLINE

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

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

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

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.

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