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E-598 - Maintenance & Inspection of Static Equipment

E-598 - Maintenance & Inspection of Static Equipment

20 days
MAT/INSPECTGB
Sessions
This course is not scheduled.
Who should attend?

Audience

    • Inspectors of the Oil & Gas industry, maintenance and inspection technicians, engineers and managers looking to acquire comprehensive inspection knowledge.

Level

  • Foundation
  • To acquire a comprehensive and practical knowledge of static equipment inspection in order to efficiently contribute to the entire scope of duties performed by an Inspection Department of an Oil & Gas company.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • use and explain pressure vessels international rules and regulations,
  • identify materials comprising equipment, their composition, their mechanical characteristics and select the most appropriated material for a given Oil & Gas application,
  • describe the various welding processes and their limits,
  • identify most appropriate non-destructive or destructive testing for the different modes of degradation and perform several simple non-destructive testing,
  • list the main characteristics and types of corrosion of metallic materials used in the Oil & Gas industries, describe protection means against each type of corrosion and implement associated monitoring.
Course Content

Module 1: INSPECTOR OCCUPATION & STATUTORY REGULATIONS RELATING TO PRESSURE VESSELS

5 days

  • Introduction to production facilities inspection:
  • Impact on safety, pressure vessel integrity, accident analysis.
  • Inspector occupation:
  • Duties & organization of inspection services: inspector role and responsibilities.
  • Inspection plan: definition, set-up, implementation.
  • Inspection report. Interaction with the other departments.
  • Statutory regulations applicable to pressure vessels:
  • Main regulatory texts. Area of application and regulatory context of pressure vessels.
  • Roles and responsibilities of various parties. Managing feedback and lessons learnt.

Module 2: METALLURGY & MATERIALS, WELDING

5 days

  • Metallurgy:
  • Ferrous and non-ferrous metals.
  • Structures and behavior of metals and alloys at service conditions for static equipment.
  • Evaluation of the mechanical characteristics required for predictable behavior at service conditions.
  • Most widely used metals and metal alloys in production facilities: steels, their composition, structure and behavior at service conditions.
  • Steels: HIC-resistant, CRA resistant, cupro-nickel, aluminium bronze.
  • Effect of heating and cooling on steels: current heat treatments resulting from welding or deliberately applied.
  • Common defects in steels.
  • Boilermaking - Welding:
  • Current cutting, forming and welding processes; impact on metals structure.
  • Post-welding heat treatment.
  • Identification of welding defects in welded assemblies using non-destructive checks and destructive tests on weld test pieces.
  • Qualification of welding procedures and welders.
  • Technique for the permanent assembly of heat exchanger bundle tubes and tube plates: roll and mechanical expansion.
  • Case study.

Module 3: CONSTRUCTIVE TECHNOLOGY, NON DESTRUCTIVE & DESTRUCTIVE TESTING

5 days

  • Equipment construction technology:
  • General information on static equipment.
  • Type of pressure vessels and pressurized accessories.
  • Drawings: reminder on PFD, P&ID, Isometrics reading.
  • Introduction to construction codes and standards:
  • Rules & regulations application areas, standards, harmonized standards, professional guides.
  • Notions of materials strength and pressure vessel shells calculations. Safety and welding margins.
  • Construction monitoring, destructive and non-destructive testing.
  • Notions of strength test.
  • Introduction to relevant codes and standards (ASME).
  • Techniques for non-destructive and destructive testing:
  • Standard faults in external and internal walls.
  • Principles, possibilities and areas of application of main NDTs: visual, sweating, magnetic crack detection, ultrasound, X-ray, sealing, acoustic emission.
  • Review of innovative NDTs: digital radio, phased array, TOFD, IRIS, MFL, intelligent pigging, ROVs, drones, reinforced visual inspection.
  • Implementation in equipment inspection: on base materials and components, during production, on acceptance, in operation.
  • Principles, possibilities and areas of application of destructive test methods.

Module 4: CORROSION PREVENTION IN PRODUCTION FACILITIES

5 days

  • Definition and mechanisms of corrosion:
  • Wet corrosion, dry corrosion.
  • Elements of electrochemistry.
  • Cost of corrosion: both financial and human, impact on safety.
  • Common types of corrosion: origin and development process, possible methods of prevention.
  • Types of corrosion encountered in the Oil & Gas industry:
  • Case studies of corrosion observed in Oil & Gas installations: identification of the types of corrosion and suggested remedial treatments.
  • Corrosion prevention:
  • Design of equipment; choice of materials; corrosion inhibitors; anti-corrosion coatings and systems.
  • Cathodic protection with sacrificial anodes or imposed current.
  • Methodology and control of processes. Control of process and environmental parameters.
  • Corrosion monitoring:
  • Corrosion coupons and probes; non-destructive testing of wall condition.
  • Corrosion monitoring plan.
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Ways & Means
  • Numerous industrial case studies and practical exercises.