Failure Analysis & Repairs of Piping & Vessels

EIM/ITRES-E

Who should attend?

  • This course introduces the repair works procedures of metallic piping as well as pressure vessels in the petroleum and chemical industries.
Audience :
  • Engineers and Technical Staff involved in safe operation and integrity of pressure vessels and piping installed in refineries, chemical and petrochemical plants.

Level : Discovery

Course Content

  • INTRODUCTION TO METALLURGY & CORROSION

      • Ferrous and non-ferrous material: mechanical properties and chemical composition.
      • Plates, forging, castings, piping, rolling, welding, post weld heat treatment.
      • Standards and international codes. Pressure vessel manufacturing.
      • Definitions and basic mechanism: wet corrosion and dry corrosion.
      • Introduction to corrosion: main types of industrial corrosion: uniform, pitting, crevice, intergranular, stress corrosion cracking, corrosion-erosion, galvanic, selective, corrosion under isolation.
  • INSPECTION & PREVENTION

      • Non-destructive testing, PT, MT, UT, IRIS, phased array, eddy current, RT.
      • Review specific hydrotest and leak test for towers, piping, heat exchanger, furnaces and boilers.
      • Anticorrosion painting and coatings, TSA. QA/QC: surface preparation, porosity control.
      • Insulation with appropriate QA/QC.
      • How to organize corrosion monitoring: guide to the development of an inspection program.
  • PRESSURE EQUIPMENT REPAIR WORKS: GENERAL PROCEDURES

      • Review of the technical inspection file: materials, heat treatments, identified degradation methods, history, construction code.
      • Development of a repair method: sand blasting, cutting, forming, welding, heat treatments, NDT: criticality of the repair work.
      • Welding processes SMAW, GTAW, GMAW: advantages and drawbacks. WPQR, WPS, WPQ.
      • Hot tapping, nozzle reinforcements, weld overlays, cladding, temporary clamping.
      • Preheat, post weld heat treatments.
      • Safety issues: hot works, height, simultaneous operation; working in confined spaces.
      • Examples of actual repair works (team works):
      • Cracking of a neutralization tower.
      • Tubes plugging of tubular heat exchanger.
      • Modification of a soda concentrator.
      • Degradation of a petrochemical furnace.
      • Replacement of pipe sections.
      • Execution of a "hot tap" repair.

Learning Objectives

  • Upon completion of this course, the trainees will be able to:
  • participate in the development repair procedure related to piping and pressure vessels,
  • list the main industrial corrosion types,
  • identify the safety issues related to hot work and working inside a vessel,
  • list the main practical procedures for temporary or long term repairs,
  • understand & supervise welding, post weld heat treatments, non destructive testing, inspection file update.

Ways & Means

  • Active teaching methods are used to promote shared experience.
  • Wide use of samples, videos and pictures to develop practical case studies for pressure equipment.
  • Actual accidents in refineries and chemical plants are analyzed.