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This course provides an opportunity to learn from the practical experience and vast knowledge of the instructor and to gain insight into proven practical methods that can be applied for assessing and extending equipment useful life.


 
Course Outline
Most practising engineers and technologists have had little or no formal academic training on failures, failure prevention and repair of pressure vessels, piping, boilers and rotating machinery.  There are no undergraduate programs to cover this subject in North America, and only a handful of universities offer graduate courses in this area.  Most reliability practitioners have formal academic training in other technical disciplines and become experienced in areas of failure prevention by virtue of their job training and work experience.  This course provides an opportunity to learn from the practical experience and vast knowledge of the instructor and to gain insight into proven practical methods that can be applied for assessing and extending equipment useful life. 

An integrated approach for examining clearly illustrated field failures and application of the knowledge in preventing failures and reinforced by case studies is presented.   The case studies vividly describe sequential repair procedures enabling participants to learn their real options before starting to rip out sections of pipe and machinery.  Reliability in design, manufacturing and maintenance is also examined.  The enhanced reliability can significantly reduce overall costs because of reduced support costs due to fewer failures.  Additionally, costs associated with catastrophic accidents which are potentially enormous and include regulatory and legal risks are eliminated.

Objective To provide participants with failure and repair examples allowing reliability improvement in pressure vessels, boilers, piping and rotating machinery. 

Who Should Attend Plant managers, process and plant design and operations engineers and technologists, manufacturers, repair organizations, consulting engineers involved in reliability, maintainability and safety, maintenance engineering personnel particularly from pulp and paper, oil and gas, and power plants, regulating agencies personnel, and other individuals whose responsibilities include repair and reliability of pressure vessels, boilers, piping, tanks, compressors, turbines, heat exchangers, digesters, valves and gears.

Program Outline Faculty: Nabil Al-Khirdaji, Kappa Associates
               International
Day I Registration and Coffee
Welcome and Introduction

1.1          Overview
• Operability and maintainability
• Mechanical integrity
• Codes, standards, and regulations
• Equipment failure causes
• Pressure vessels and boilers failure statistics
• Consequence of failure

1.2  A      Behaviour of Metals Under Stress
• Metal types, characteristics
• Stress/strain criteria and curves
• Material degradation processes
• Thin-walled and thick-walled vessels

1.3          Regulations, Codes and Standards

1.3 A       Introduction to ASME Codes
• Boiler and pressure vessel act and regulations
• Operating engineers act
• ASME pressure vessel-section III, section VIII, Div.1, Div.2 and Div.3; Section IX
• ANSI B31.1, B31.3, B31.4, B31.5, B31.8 piping
• ANSI B16.5, B16.9, B16.10 valves, flange types, gaskets fittings
• API RP 572 inspection of pressure vessels
• API RP 571 conditions causing deterioration and failure
• API RP 579 fitness-for-service

1.4          Basic Design of Pressure Vessels
• Types of construction      
• Design pressure and temperature
• Maximum allowable working pressure
• Criteria for choice of materials of construction
• Nozzles, closures, lifting lugs
• Supports and foundations
 
1.5          Basic Design of Piping Systems
• Codes, standards and regulatory requirements
• Design considerations
• Loads on piping systems
• Calculations-guidelines and rules of thumb
• External loads on piping
• Piping systems configuration and sizing
 
Day II
2.1          Change Control Management
• Change control policy and procedures
   - process changes
   - plant changes
   - assessment and authorization
   - documentation
• Illustrative change control procedure

2.2          Failures in Pressure Vessels, Piping and Boilers
• Overview of failure modes
• Corrosion and corrosion protection
• Fatigue  
• Stress corrosion cracking
• Conjoint corrosion
• Creep
• Hydrogen embrittlement
• Brittle fracture
 
2.3          Piping System Vibration and Failure
• Causes of piping system vibration and failure
• Related standards and acceptance criteria
• Measurement methods and analysis
• Experimental and analytical diagnostic techniques
• Corrective methods and options
 
2.4          Failures in Rotating Equipment
• Failure evolution process
• Bases for the detection of faults in rotating machinery
• Principles of rotor dynamics and balancing
• Bent shafts-thermal distortion, large unbalance force
• Cracked shafts-vibration caused by fatigue-induced cracks
• Shaft misalignment
• Bearing lubrication, misalignment, and rubbing
• Excessive forces and moments by connected piping
• Equipment base plate grouting
 
2.5          Failure Prevention
• Plant integrity audits
• Corrosion monitoring and control
• Process and operating changes
• Engineered changes and controls
 
2.6          Testing and Monitoring
• On-line stress/strain monitoring
• Non-destructive examination
• Acoustic emission
• Corrosion monitoring
• Periodic pressure test and examination
 
Day III 3.1          Inspection, Testing and Repair Regulations, Codes and Practices
• API 570-Piping Inspection Code-inspection, repair, alteration, and rerating of in-services piping systems
• Inspector qualification: API body of knowledge
• Criticality-inspection interval and extent
• Cost considerations
• Article Pipe Wall Thickness and Risk Based Inspection

3.2          Evaluation of Inspection Data
• Data quality
• Corrosion rate calculations
• Remaining life calculations
• Article Numerical Method of Ranking of Defective Pipelines Sections Based on
• In-Line Inspection Data
• Common problems and what to watch for

3.3 A       Fracture Mechanics

3.3 B      Fitness-For-Service
• API RP 579 fitness-for-service
• Fracture mechanics and mode of failure of material
• Flaw characterization, growth, stability
• Factors of safety
• Disposition versus repair and life management
 
3.4          Maintenance Programs
• Inspections
• Repairs and alterations
• Quality control programs for B&PV Act 32(3) exemptions
• Relocation and retirement of equipment
• Accident investigation
 
3.5          Pressure Relief Devices

Day IV 4.1          Rerating Piping and Pressure Vessels
• Overview
• Guidelines
• Regulatory requirements

4.2          Estimation of Consequences of Pressure Vessels and Piping Failures
• Stored and potential energy available
• Qualitative effects of energy release
• TNT equivalents
• Scaled distance; Hopkinsons rule
• Bleves: vapour cloud explosions
• Pressure relief device requirements

4.3          Workshop-Piping and Equipment Failures
• Piping component design failure
• Piping modification failure
• Repair of thinned vessel
 
4.4          Repair Methods for Piping/Vessel Defects.
 
Concluding Remarks and Final Adjournment
 
There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.
 
After Participating in this Course, You will be Able to:
  • Conduct thorough detailed inspections to avoid failures
  • Prevent the propagation of cracks with the knowledge acquired at the seminar about why cracks occur in the first place
  • Plan and carefully supervise repair procedures with the insight gained from the seminar
  • Select the non-destructive testing methods for your situation and develop confidence to correctly interpret test results
  • Implement the repair procedures that you glean from case histories that comply with the code and are economically efficient
  • Assess and extend equipment useful life by employing proven practical methods that you learn from the seminar instructor 
  • Improve reliability and availability of your pressure vessels, boilers, piping and rotating machinery by preventing failure
Daily Schedule:
8:00    Registration and Coffee (1st day only)
8:30    Session begins
4:30     Adjournment
Prerequisites & Certificates
Pre-Requisites

Certificates offered

2.4 CEUs / 24 PDHs


Cancellation Policy
To withdraw from a course, you must send a request, in writing, with the official receipt to our office. Fifteen or more business days in advance: full refund less $50.00 administration charge. Five to fifteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. Credits are transferable within your organization. In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost.
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Here are some reviews of the training vendor.
The course was very well presented and the course instructor was absolutely amazing.
Reviewed by 2013
Our instructor, Stephen Lamming, was outstanding and a true expert in his field. He was able to complement the technical air monitoring information with practical real life examples which was highly beneficial. He is an excellent communicator and was highly interactive with the course attendees. This course was recommended to me because Stephen Lamming does an outstanding job. I was very impressed with this course and have subsequently recommended it to my colleagues.
Reviewed by 2012
Would have liked more interactive problem solving.
Reviewed by 2011
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