INTRODUCTION
Pressure vessels, heat exchangers, storage tanks and piping systems represent over half the capital investment in a typical process plant. The purpose of this programme is to present the requirements for the relevant industry standards and practices regarding inspection, monitoring
and maintenance of various types of equipment.
The programme will introduce relevant API standards that provide guidelines for developing inspection and maintenance programmes for process equipment as well as the instructions for appropriate repairs and alterations.
It is deemed very important for the delegates to have
full understanding of the material degradation processes, risk analysis of equipment failures and available prevention and remedial technologies.
The programme will include many workshops
with solving real problems from industrial practice which will enable discussions and exchange of experiences.
WHO SHOULD ATTEND?
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Process, chemical and mechanical engineers working in petrochemical and process industry, including oil refineries and gas production companies
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Operation, technical service and maintenance professionals from various processing plants involved in everyday operation, control, inspection and maintenance
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Engineers and consultants dealing with planning of new production lines and retrofitting plants and introducing new technologies
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Technical professionals responsible for maintenance and repair of equipment
PROGRAMME OBJECTIVES
Upon completion of this programme, delegates will be able to follow the guidelines for requirements of the relevant industry standards and practices to:
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inspection, monitoring and maintenance of pressure vessels, heat exchangers, storage tanks and piping systems
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development of efficient maintenance programmes for process plant equipment
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procedures and technologies recommended for repairs and alterations to process equipment
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maintenance and troubleshooting of rotating machinery: pumps, compressors, turbines
TRAINING METHODOLOGY
The programme will be conducted along workshop principles with formal lectures and interactive worked examples including. The emphasis in the programme will be on the explanation of all technical phenomena and
providing answers to problems that are encountered in everyday industrial practice related to maintenance, repair
and alterations of process equipment.
Each learning point will be reinforced with practical examples. There will be ample opportunities for active discussion and
sharing professional experiences and exchange that will help solidify the gained knowledge. All programme materials will be provided.
PROGRAMME SUMMARY
This programme will provide requirements for effective and safe maintenance of process plant and equipment. Delegates will be introduced
into various practical
problem solving aspects of stationary and rotating equipment as encountered in everyday industrial practice. Discussed also will be the troubleshooting methodologies applied to rotating machinery: pumps, compressors
and turbines.
The focus of the programme will be on developing a practical understanding and familiarity with inspection and maintenance requirements for pressure vessels, storage tanks and piping systems in process plant applications.
Several workshops with examples to be solved as a
team work will be included in the programme. They will illustrate the concepts discussed and also provide delegates with
necessary experience in applying them.
PROGRAMME OUTLINE
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DAY 1 -
OVERVIEW OF PROCESS EQUIPMENT
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Overview of main equipment in process plant
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Specifics of stationary and rotating equipment
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Equipment operating conditions and deterioration mechanisms
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Risk assessment and criticality list
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Risk based inspection planning (API 580)
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Fitness for service assessment
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Overview of API 579/ASME FFS
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Workshop: Examples and solutions
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DAY 2 -
INSPECTION METHODS AND ACCEPTANCE CRITERIA
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Pressure Vessel Inspection Practices (API 510)
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Storage tank inspection, repair and alteration (API-653)
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Inspection Techniques for Piping and Components (API 570)
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Valve inspection and testing (API-598)
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Corrosion determination using NDT methods
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Consideration of cracks and potential fractures
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Evaluation of remaining life of equipment
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Workshop: Examples and solutions
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DAY 3 -
MAINTENANCE PROCEDURES
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Assessment of leaks in pressure vessels, tanks and heat exchangers
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Leak repairs and re-tubing considerations
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Maintenance and protection of pressure vessels and heat exchangers
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Commonly applied cleaning methods
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Piping system leaking detection
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Pipeline maintenance using pigging devices
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Guidelines for hot bolting and hot tapping
Workshop: Examples and solutions
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DAY 4 -
REPAIR AND ALTERATION
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Pressure vessels repair and alterations
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Welded repairs and post-weld heat treatment (PWHT)
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Re-rating of pressure vessels and storage tanks
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Piping system repair, alteration, rerating
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Valve repair and testing
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Flange joints in critical services
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Hydrotest requirements
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Workshop: examples and solutions
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DAY 5 -
MAINTENANCE OF ROTATING EQUIPMENT
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Overview of problems in operation of rotating machinery
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Vibration monitoring and measurements
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Bearing failures and lubricant temperature analysis
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Centrifugal pump cavitation prevention
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Mechanical seal maintenance
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Surge problems of centrifugal compressors
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Maintenance of gas turbines
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Summary and programme overview
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