The foundation of pressure equipment and piping design, operation, and maintenance lies in selecting suitable materials. The suitability of materials is determined by applicable Codes. The mechanical integrity, safety, and cost-effective operation of plants rely on the performance of construction materials throughout the entire lifespan of the plant. This training course, titled "Materials of Construction for Process Equipment & Piping Systems," offers a comprehensive and practical understanding of engineering materials. It provides guidance on selecting the appropriate materials for specific applications, taking into account service requirements, construction code requirements, and minimizing life cycle costs over the plant's entire lifespan. The course incorporates industry best practices and methods to ensure optimal material selection.

Course Objectives:

The key objectives of this training 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 operation

· 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?

The program should be of interest to:

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
Corrosion Resistant Alloys
High Temperature Alloys
Erosion Resistant Alloys
Specialty 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, Shaeffler 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 - the 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

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