Failures, Failure Prevention and Repairs to Static Process Equipment and Piping
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Failures, Failure Prevention and Repairs to Static Process Equipment and Piping Course
Introduction:
The integrity and reliability of process equipment and piping systems are critical for plant availability and performance, as they constitute a significant portion of plant assets. These systems often operate under hazardous conditions and are susceptible to damage mechanisms. If not adequately monitored and assessed, they can lead to major failures resulting in severe injuries and significant business losses. It is crucial to conduct inspections on process equipment and piping systems to identify any damage, characterize it, and evaluate its impact on equipment integrity.
Considering the extensive number of equipment pieces and extensive piping networks within a plant, it is impractical to inspect every single component. Therefore, a risk-based approach based on criticality must be adopted. This approach takes into account the damage mechanisms and failure risks associated with each equipment or piping system, prioritizing inspections accordingly. By focusing on critical areas, the approach ensures that resources are effectively allocated to mitigate the highest risks and prevent potential failures.
Course Objectives:
The key objectives of this comprehensive course are as follows:
· To increase the participant’s 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 Outlines:
Failure Mechanics
- Wear & Failure Mechanisms
- Imperfections and Defects
- Corrosion Mechanisms
- Failure Modes
- Fatigue
- Fretting
- Creep & Thermal Fatigue,
- Stress Corrosion Cracking, Other Modes
- Material Properties, and Selection
- Carbon & Alloy Steels
- Nickel, Titanium, and Specialty Alloys.
- Aluminum, Aluminum Alloys.
- Copper, Copper Alloys.
- Plastic Piping.
- Alternative Options-Linings, Cladding.
- Limitations and Safeguards.
- Material Selection - Economics-Life Cycle Costing.
Failure Prevention by Design
- Failure Causes – Design, Operation; Maintenance, Other Causes
- Material Properties and Selection.
- Physical Properties and Limitations of Components
- Physical Properties of Steel And Alloy Piping And Tubing
- Physical Properties of Fittings
- Basic Design
- Pressure Vessels
- Piping Systems
- Liquid Storage Tanks
- Operation And Maintenance Of Process Equipment
- Damage Mechanisms Affecting Process Equipment
Process Equipment Failures
- Failures In Pressure Vessels, Piping and Boilers
- Strength Reduction Through Material LOSS
- Case Histories
- Piping System Vibration
- Mechanical & Flow Induced Resonance
- Transient Hydraulic Pulsation
- Pipe Supports and Restraints
- Wind Loading
- Industry Practices For Failure Prevention
Inspection, Assessment and Maintenance.
- Inspection strategies plans and procedures – risk based inspection (API 580).
- Developing AN RBI Plan.
- Fitness-For-Service Assessment (API 579).
- NDT Methods and Techniques.
- Probability of Detection.
- Damage Characterization.
- Selecting The Correct Technique(s).
- Pigging Of Pipelines.
- Smart Pigging.
- Cleaning.
- Operational Procedures.
Operation and Maintenance
- Maintenance Programs.
- Repair And Alteration of Pressure Equipment and Piping
- Rerating Piping and Pressure Vessels.
- Estimation of Consequences of Pressure Vessels and Piping Failures.
- Failure Analysis Techniques.