15-19 January, February, 2017

Transcription

1 Training Title API 571 DAMAGE MECHANISMS 5 days Training Venue and Dates API 571 Damage Mechanisms Trainings will be conducted in any of the 5 star hotels January, February, 2017 $4,000 Dubai, UAE Training Fees 4,000 US$ per participant for Public Training includes Materials/Handouts, tea/coffee breaks, refreshments & Buffet Lunch. Training Certificate Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees. TRAINING OVERVIEW In order to proactively improve and enhance the safety reliability and profitability chemical plants and oil field related plant and machinery, it is necessary to understand where why and how the corrosion related mechanisms cause damage which eventually lead to sudden failures, such an understanding of failure mode helps to decide If a change in process is essential Or the change in equipment or material is warranted Or any such change would not have undesirable effects on safety and reliability of plant operation, as every mistaken decision would cost a fortune. This course is an excellent combination of metallurgy, failure analysis, fractography, and Corrosion Sciences. Also an introduction to ISO Fitness-for-Service (FFS) assessments are quantitative engineering evaluation performed to determine the structural integrity of an in-service systems containing a flaw or damage. The FFS help engineers to make run-repair-replace decisions to help ensure that the system inservice can continue to operate safely. Fitness-for-Service intends to ensure safety of plant personnel and public while older equipment continues to operate, to provide technically sound fitness-for-service assessment procedure to ensure that different service provide furnish consist life prediction, and to help optimize maintenance and operation of existing facilities.

2 FFS is an integration of three disciplines; these are materials, inspection, and mechanical analysis. The course will discuss the three technological triad required for fitness-for-service assessment, and apply that on the piping and pressure vessels systems. All of the above will be presented in connection with the related codes and standards. Examples will be presented using the known methods and programs. Delegates are asked to bring with them their own laptops to practice some of such exercises COURSE OBJECTIVES From Corrosion Basics learn all metal under a given environmental or operational conditions do not behave in the same manner and when the environment changes, the same metal s behavior abruptly changes. From the excellent tools available now in Electrochemistry we are able to follow the failing patterns of metals; and from NDE methods we are able to assess what is going on. Metallurgical and optical tools as Microscopy, enable us to know what caused the damage This course blends all these modern technology and theory to get an inside out picture of the pains and aches of metals and materials which are subjected to high pressure, temperature and aggressive chemical situations that prevail in any oil field operation. The diagnosis is available on line and offline before or after failure and we get to know how to treat it. The participant will learn the importance of FFS for piping systems and pressure vessels The participant will learn the principles of FFS, and how to apply it on Piping system and Pressure vessels. The participant will learn where to find and how to calculate data necessary for FFS application The participant will learn how to use the results of FFS to take right decision concerning the operation, shutdown, interval of inspection, repair of the existing inservice piping The participant will learn how to evaluate the integrity and remaining life of piping systems and pressure vessels. The participant will have a chance to practice some the FFS assessment methods during the course. TRAINING METHODOLOGY A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. All presentations are made in excellent colourful power point. Nearly a hundred graphics on failure would enable the participant to Identify active damage mechanism

3 Detect the type and extent of damage using NDE methods Identify potential mode of leaks rupture and collapse and structural failures Estimate the progress of damage Monitor and control the progress of damage mechanism A video on Corrosion in action will be shown Some practical and Demo will be made on the last day A video on corrosion will be shown. 30% Lectures 30% Workshops and work presentation 20% Group Work& Practical Exercises 20% Videos& General Discussions WHO SHOULD ATTEND It is an highly intensive & interactive training session. An excellent compilation of material sciences not available in any curriculum or text and therefore highly recommended to all operational and maintenance and process engineers who are dealing with plant and machinery made of different metals and material every day; for plant inspectors who like to know the changes, losses, deformation and corrosion that takes place when the reactors are operating; the subtle and micro damages that add up cay by day and eventually reach an intolerable limit. All technical staff who are working in midstream operation, and gas plants. To all those interested in knowing about damage mechanism covered by API 571. To those involved in repair alteration etc and wish to assess the condition of aged plant before proceeding. Finally for all those interested to know something about failure analysis. A specially tailored seminar with lots of graphics not to miss. This is a value added package with practical, test papers, quiz etc COURSE OUTLINE CORROSION MECHANISM IN OIL AND GAS INDUSTRY API 571 INTRODUCTION Most of the refineries in the Middle East are more than 30 years old and some even have crossed fifty. It has given a false impression that the plants would continue to run for ever without any problem as before although it is forgotten that many input variables have taken place and stringent quality control on output has warranted several process changes and this has deviated from design parameters and conditions. All the years failures were attributed to mechanical wear out and normal ageing but recent findings and theories of corrosion tell us that materials are also subjected to stress and fatigue and may fail like human beings anytime without warning. Recent devastations in many refineries in spite of Risk Based

4 Inspection tell us that our understanding of material limitation is still very poor and running the plant without such vital information is a question on plant reliability and safety. This course is designed to take a break and learn why problems persist in different parts and plants and machinery and how to address them By Proper Material Selection. SCOPE In the wake of declining global economy the need for careful asset management is gaining much importance as health and safety. Particularly where old pipelines and equipment need repair alteration, re-rating.the question of an economic approach and a calculated risk in utilizing new material is warranted. The word material does not restrict itself only to metals and alloys but includes nonmetallic chemicals, and devices that help to improve plant reliability. Days are gone when one department designs or orders and someone uses them. Material selection is becoming a corporate responsibility including process engineers, maintenance staff, laboratory personnel, inspection and safety department and not forgetting the Corrosion engineer- each of them have something say about problems and prospects of closing alternatives in the case of failures. The finance controller and the supplier work out the best solution. Thus a decision tree is evolved to arrive at a right choice. Material selection is thus a challenging task that works to the safety and benefit of all concerned. WHO SHOULD ATTEND? Excellent course specially designed for process engineers, maintenance staff, laboratory personnel, those involved in design and material selection. This is a course that embraces all API standards such as 510, 570, 571 and introduction to ISO METHODOLOGY All lectures are presented as colorful power point and the student manuals are PDF format of the same. Photographs of case studies of each failure will be more illustrative than wordings. At the end of each module here will be tests and the student can take it as home assignment if he is preparing for exam. Candidates who attended the course have successfully passed in API 571 COURSE OUTLINE Day 1 Aladdin s lamp- changing new one for old

5 What is problem with present metallurgy?-the metallurgy of carbon steel, the material widely used.-the wrong concepts held so far. Metals are not for ever-desirable physical properties of metals.-the alterability of physical properties Grain boundary and the basics of TTT diagram Crystal structure & grain boundaries Carbon the good and bad about it Types of carbon steel Physical Properties of metals Addition of Cr Ni etc and effects stainless steels Heat treatment and welding- how it affects physical properties Day 2 The unforeseen forces at play- study of environment Elements of nature vs man made giants the clash of the Titans Environment to which metals normally are exposed-failures that are normally reported- Aggressive conditions in oil and gas process-chemical reaction that take place-corrosion an irreversible process Eight types of corrosion- micro and macro-uniform or Localized Loss of Thickness - Galvanic Corrosion - Atmospheric Corrosion- corrosion in water velocity and factors- cavitationerosion-selective leaching-pitting- filliform- Galvanic corrosion-factors that enhance corrosion Special alarming situations- Corrosion Under Insulation (CUI)- Cooling Water Corrosion - Boiler Water Condensate Corrosion. CO2 Corrosion -Flue Gas Dew Point Corrosion- Caustic Corrosion- Dealloying- Graphitic Corrosion-High Temperature Corrosion [400oF (204oC)]- Sulfidation -Carburization Decarburization- Metal Dusting- Fuel Ash Corrosion - Nitriding- Environment Stress Assisted Cracking - Chloride Stress Corrosion Cracking (CI SCC)- Corrosion Fatigue - Caustic Stress Corrosion Cracking (Caustic Embrittlement)- Ammonia Stress Corrosion Cracking- Liquid Metal Embrittlement (LME) - Hydrogen Embrittlement (HE) --Bacterial and microbe induced corrosion Day 3 Gas and oil processing units-process Metallurgy Some key processing stages and problems failures and case studies Desalters-chloride acid corrosion Crude towers overhead top trays-cat. reformers-hcl corrosion- SS 300,400 series

6 Crude towers, FCC, hydrogen reforming, hydro-processing, tail gas units-amine corrosion Crude vc heater tubes transfer- naphthenic acid corrosion-ss317 L and high Mo content Desulphurizers, hydro-treaters- High Temp Corrosion of CS, 400 series FCC gas plants, coker, Strippers-sour water corrosion of 300 Series and Duplex Stainless steel Boilers and heaters-high temperature and H2/H2s Corrosion High heat exchangers- amine stress corrosion cracking- Cu alloys- 400 series St Steels Hydro-processing unit- sour water service HF alkylation units- Cr/Mo alloys- Hydrogen embrittlement Carbon steel tanks and piping of refrigeration units- ammonia stress corrosion cracking Process piping- alkylation unit-alloy400 Waste water management units and piping- mercury LME Day 4 Specific refining industry damage mechanisms General- Uniform or Localized Loss in Thickness Phenomena - Amine corrosion-ammonium Bisulfide Corrosion (Alkaline Sour Water)-Ammonium Chloride Corrosion- Hydrochloric Acid (HCl) Corrosion High Temp H2/H2S Corrosion - Hydrofluoric (HF) Acid Corrosion- Naphthenic Acid Corrosion (NAC) Phenol (Carbonic Acid) Corrosion- Phosphoric Acid Corrosion.-Sour Water Corrosion (Acidic)- Sulfuric Acid Corrosion- Cracking failures -Environment Assisted Cracking- Polythionic Acid Stress Corrosion Cracking (PASCC)- Amine Stress Corrosion Cracking - Wet H2S Damage (Blistering / HIC / SOHIC / SCC - SWC Hydrogen Stress Cracking HF- Carbonate Stress Corrosion Cracking - Other Mechanisms- High Temperature Hydrogen Attack (HTHA)- Titanium Hydriding Stainless steel a misnomer Properties of stainless steel contrasted with carbon steel Evolution of a super metal- four major grouping and properties Specific failure patterns and situations of stainless steel Martensitic stainless steel and its application in flow lines, manifolds etc Stainless steel for H2S, CO2 Chloride Wet gas metallurgy

7 Day 5 Protection measures for carbon steel and other material selection options Coating- organic, metallic, plating and anodizing Selection, cost and economics Cathodic protection its advantages and limitations Inhibitors types, application, cost and limitations Design changes Application of lining and cladding Fiberglass polymers as piping and storage tanks-applications Three causes of failures Application of rubber, CPVC UPVC in piping Non ferrous metallurgy and Other alloys Videos, Relevant Case Studies, Group Discussions, Last Day Review, Pre & Post Assessments will be carried out...