Materials of Construction for Process Equipment and Piping Systems Training
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Materials of Construction for Process Equipment and Piping Systems Training Course
Introduction:
The foundation of the design, operation, and maintenance of pressure equipment and pipelines is appropriate material selection. The applicable Codes regulate what constitutes acceptable materials. Throughout the plant's life cycle, the in-service performance of the building materials determines the mechanical integrity, safety, and economical operation of the plant. In addition to offering advice on how to choose the best building materials for a given application while also meeting construction code requirements, service requirements, and the least amount of life cycle cost over the course of the plant, this course gives students a thorough and practical understanding of engineering materials.
Course Objectives:
The key objectives of this course are as follows:
- Assist participants to clearly understand the appropriate selection of materials of construction for pressure equipment
- Enable delegates to understand how materials affect safe, reliable, and cost-effective plant operations.
- Enhance participants' awareness of key requirements of relevant design and operation standards and industry practices such as ASME B&PVC and B31.3; ASTM Material Specifications, API 571, 580, 581, 578 and 579, and others.
- Provide guidelines to participants to identify and locate in-service degradation and appropriate tools for condition assessment and making sound run/repair/replace decisions.
- Make participants recognize that although all flaws detected by inspection must be evaluated, not all flaws need to be repaired.
- The proper application of API Std 579-1/ASME FFS-1 for fitness-for-service assessment may obviate the need for some repairs and result in reduced maintenance cost and downtime.
Who Should Attend?
This course is particularly valuable for:
- Refinery, Petrochemical and Process Plant Mechanical and Process Engineers
- Technical Professionals
- Inspectors, maintenance personnel
- Project and Consulting Engineers
- Engineering and Technical Personnel involved in plant mechanical integrity and reliability.
Course Outlines:
- Engineering Materials - Types and Properties
- Engineering Materials I - Overview
- Metals - Ferrous and non-ferrous
- Carbon steel
- Alloying elements added to iron base - carbon, manganese, and silicon
- Effect of alloying elements on end properties and on fabrication processes
- Impurities and their effect - sulfur, phosphorus
- Alloy steel
- Effects of alloying elements
- Stainless steels
- Specialty alloys
- Corrosion-resistant alloys
- High temperature alloys
- Erosion resistant alloys
- Engineering Materials II
- Refractory materials - Types and applications - Examples: Titanium and zirconium
- Clad Materials - Types; production methods; and typical applications
- Composite materials - Classes, types and applications
- Non-Metallic materials - Plastics, ceramics
- Surface engineered coatings/overlays - Types, specifications and applications
- Organic coatings
- Metallic coatings
- Corrosion-resistant cladding
- Corrosion-resistant / hard-surface welding
- Thermal spray coatings
- Plasma transferred arc (PTA) welded overlays
- Metallurgy Basics
- The structure of metals and alloys
- Imperfections in metals and alloys
- Chemical composition - Unified numbering system (UNS)
- Physical properties - melting temperature, the thermal conductivity, electrical conductivity, the coefficient of thermal expansion, and density
- Mechanical properties - Base metals, filler metal and completed welds
- Tensile and yield strength, ductility, hardness and toughness
- Heat treatment and effect on material properties
- Material Forming and Fabrication
- Forming and forging
- Casting
- Welding processes - main technologies and consumables currently used in industry
- Weldability - Carbon equivalent; Schaeffler and WRC diagrams
- Preheat and Post-Weld heat treatment (PWHT) - Code (B&PV and B31) rules
- Weld imperfections (discontinuities) commonly encountered with welding processes
- Overview of ASME B&PVC Section IX 'Welding and Brazing Qualifications'
- This Section contains rules relating to the qualification of welding and brazing procedures as required by other code sections for component manufacture
- Welding procedure specification (WPS)
- Procedure qualification record (PQR)
- Welder performance qualification (WPQ)
- Materials Selection and Application
- Material Selection Process and Guidelines
- Life cycle cost considerations
- Factors in material selection in petroleum refineries- type of refinery; type of crude oil processed; service conditions in specific process unit/application, expected service life
- Oxidation resistance - scale formation
- Guidelines on the maximum temperature of use of carbon steel and alloy materials
- Creep properties - The Larson-Miller parameter (LMP)
- Fatigue properties - Fatigue design (S-N) curves
- Materials Standards and Codes
- ASME Boiler and Pressure Vessel and Piping Construction Codes
- Allowable stresses
- Constraints and limitations
- P-Number identificat
- ASTM: “ Some common material specifications for piping, plates, forgings, and castings
- Materials Standards and Codes (continued)
- API RP 941 - Steels for hydrogen service at elevated temperatures and pressures in petroleum refineries and petrochemical plants
- NACE MR 0175/ISO 15156 'Petroleum and Natural Gas Industries - Materials for Use in H2S-containing Environments in Oil and Gas Production - Parts 1, 2 and 3'
- Oxidation resistance - scale formation
- NACE MR0103 'Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments'
- PIP (Process Industry Practices) Standards - Example: PIP Piping Material Specification 1CS2S01 Class 150, Carbon Steel, Socket Weld, 0.125 C.A. Process.
- Fatigue prop