This course offers a thorough and hands-on understanding of how to choose the right building materials for particular applications while also meeting life cycle costs, construction code requirements, and service requirements. Process equipment is an essential component of any installation in a refinery, petrochemical plant, or power plant. Whether the right materials were used to make the process equipment determines whether such facilities succeed or fail. The materials ought to survive the anticipated design life and be appropriate for the necessary Process, corrosive environments, temperature considerations, etc. Achieving this at the lowest possible cost while taking safety and dependability into account, as well as adhering to material codes and regulations, is important.

Course Objectives:

On completion of this course, the trainee/s will be competent in:

Enable delegates to understand how materials affect safe, reliable, and cost-effective plant operation.
Provide guidelines to participants to identify and locate in-service degradation and appropriate tools for condition assessment and making sound run/repair/replace decisions.
Main factors in deciding the suitable material for a given service.
Understanding of Basic metallurgy
Various metals, alloys their Applications and Limitations
Material suitability for various Process applications
Factors governing material choice :Corrosion, Temperature, and other factors
Weldability and fabrication considerations
Materials for pressure vessels
Materials for Heat exchangers
Piping materials
Materials for critical applications-Sour Service, Caustic Service, Hydrogen service etc.
Codes and standards in material selections
Typical ASTM specifications and grades.
Selection of alternative materials. Do’s and Don’t in selecting material substitutes

Who Should Attend?

This course is ideally suited for Process engineers, designers, technical managers, Quality control persons corrosion engineers, and all those involved in materials selection and evaluation of materials for Petroleum, Petrochemical, Power, and other process industries. The plant engineers Inspection people and maintenance engineers related to pipelines, tanks, pressure vessels, etc. will find this course quite valuable.

Course Outlines:

Engineering Materials - Types and Properties
Engineering Materials
Metals - Ferrous and non-ferrous
Carbon steel, Alloy steel
Stainless steels, Corrosion resistant alloys
High-temperature alloys, Erosion resistant alloys
Refractory materials - Types and applications
Composite materials - Classes, types, and applications
Non-Metallic materials - Plastics, ceramics
Mechanical properties
Tensile and yield strength, ductility, hardness and toughness
Heat treatment, Material Forming, and Fabrication
Forming and forging, Casting, Welding processes
Weld imperfections commonly encountered with welding processes
Materials Selection and Application
Material Selection Process and Guidelines
Life cycle cost considerations
Oxidation resistance - scale formation
Guidelines on the maximum temperature of use of carbon steel and alloy materials
Creep properties, Fatigue properties - Fatigue design (S-N) curves
Material Selection for Specific Equipment
Refineries and petrochemical plants
Pressure vessels, Piping valves, and fittings
Pumps, Degradation of Materials In-Service
Material Ageing and Degradation
Indicators or symptoms of aging
Failure Modes and Mechanisms in Materials
Degradation processes, Excessive elastic deformation Fracture
Metallurgical Failure Analysis
Inspection Strategies and, on-Destructive Examination Methods
Mechanical (Structural) Integrity - Overview
Definition, scope, and key elements
Potential threats to technical integrity in a hazardous environment
Overview of API RP 580 and RBD 581 - Risk-Based Inspection
The capability of the applicable inspection method vs.discontinuity
New developments in NDE methods
Basic Considerations in the selection of the materials for a given service
Mechanical properties of metals, their relevance in engineering applications,
Effects of Alloying elements on Carbon Steels.
Heat treatments and their effects on material properties
Low alloy steels, Stainless steels, Duplex steels
Quality control requirements for materials for ASME boilers and vessels
Brief Overview of important ASTM standards.
ASME Materials of construction for process plants and equipment.
ASME Sec. II Specifications for metallic materials.
Material Inspection and material Identification
Partially Identified Materials
Impact testing Requirements
Factors governing material choice: corrosion, temperature, and other factors
Weldability and fabrication considerations
Materials for pressure vessels
Materials for Heat exchangers
Piping materials
Materials for critical applications: Sour Service, Caustic
Service, Hydrogen service
Codes and standards in material selections
Typical ASTM specifications and grades.
Difference between ASTM and ASME materials
Other Material Standards British, DIN, and JIS Specifications
Material equivalents, Material substitutions
Selection of alternative materials. Do’s and Don’t in selecting material substitutes.
Case studies in material selection techniques for various processes equipment.

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