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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
After participating in this course, you will be able to do the following:
conduct thorough and detailed inspections to avoid failures
prevent the spread of cracks
plan and supervise repair procedures
select the non-destructive testing methods for your situation
interpret test results correctly
implement economically efficient repair procedures
assess and extend the useful life of equipment
improve reliability and availability of your pressure vessels, boilers, piping, and rotating machinery

Description

Most practicing 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.

Faculty: Nabil Al-Khirdaji, Kappa Associates International

Program Outline

Day I

Registration and Coffee
 
Welcome, Introduction, Workshop Preview, Learning Outcomes and the Assessment Method

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; Hopkinson’s 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

Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

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. 

Daily Schedule:
8:00
   Registration and Coffee (1st day only)
8:30   Session begins
12:00 Lunch
4:30   Adjournment

Instructor
Nabil Al-Khirdaji
Nabil Al-Khirdaji, M.Eng. and P.Eng., is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries. Mr. Al-Khirdaji has taught well over 200 technical professional development courses and he specializes in the areas of plant integrity, petroleum refinery, and process plant equipment design and operation. He has taught in Canada, the U.S., Saudi Arabia, Kuwait, Sudan, Yemen, Oman, Abu Dhabi, Dubai and Malaysia, presenting numerous topics on the design, operation, and maintenance of process plant equipment and piping systems. He received his B.Eng. (Mechanical) degree from the American University of Beirut and his M.Eng. degree from the University of Toronto.

A registered professional engineer with the Association of Professional Engineers of Ontario, Mr. Al-Kjirdaji has over 40 years of experience in the petroleum, petrochemical, and related industries both in Canada and the Middle East. During these past 40 years, including 24 years with Shell Canada Limited, he has assumed a number of project, engineering specialist, and engineering management positions with a vast range of responsibilities. He is also mechanical program director with EPIC and holds a senior project management position with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API committee on refinery equipment, which oversees the development of engineering practices for the design, fabrication, installation, inspection, and use of materials and equipment in refineries and related processing facilities.


Prerequisites & Certificates
Pre-Requisites

Certificates offered

2.8 CEUs / 28 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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