Advanced Process Equipment Failure Management
Evaluation, Examination, and Quality Inspection
Course Overview
Process equipment, piping systems, and structural components are frequently exposed to severe operational conditions, including high or fluctuating stresses, extreme temperatures, and various forms of corrosion. Such conditions can compromise structural integrity, leading to degradation, damage, and, if undetected, catastrophic failures with potentially significant consequences for personnel, assets, and operations.
To ensure the safe and reliable performance of engineering systems under all foreseeable operating scenarios, equipment must be designed using appropriate construction materials, guided by recognized design methodologies and industry codes. Moreover, safeguards and operational controls must be implemented to prevent operation beyond the defined "design and operational envelope," alongside systematic inspection programs to detect damage, assess its nature, and evaluate its impact on the equipment’s Fitness for Service (FFS).
This training Course will cover:
- Mechanical testing of structures and materials
- Identification and understanding of common structural failure modes
- Principles of structural integrity assessment and damage mitigation
- Best practices for safe operation and control of process equipment
- Inspection techniques and non-destructive testing (NDT) methods
Course Objectives
By the end of this Training, participants will be able to:
- Understand and predict degradation mechanisms affecting process equipment and their potential to cause significant failures.
- Appreciate the interrelationship between design, operation, and maintenance in ensuring mechanical integrity.
- Recognize and evaluate various mechanical failure mechanisms, including fracture, fatigue, creep, and corrosion.
- Apply basic principles of inspection and NDT techniques effectively in industrial settings.
- Implement failure mitigation strategies aligned with industry best practices.
Course Audience
This Course is designed for:
- Engineers and technical staff involved in selection, design, fabrication, operation, or supervision of mechanical equipment and components.
- Professionals seeking practical understanding of structural integrity evaluation.
- Operation, technical service, and maintenance personnel in process industries.
- Engineers and consultants engaged in plant design, retrofitting, or implementation of new technologies.
- Project managers, asset managers, and technical professionals responsible for equipment maintenance, repair, and lifecycle management.
Course Methodology
This Course adopts a workshop-oriented approach, combining formal lectures with interactive case studies and hands-on exercises. Emphasis is placed on practical problem-solving, explanation of technical phenomena, and addressing real-world challenges encountered in industrial practice related to structural failure and mitigation techniques.
Active discussions, experience-sharing sessions, and collaborative problem-solving exercises ensure that participants consolidate their knowledge and develop practical skills applicable in their professional environment.
Course Outline
Day 1 – Materials Testing and Failure Analysis
- Course objectives and overview
- Mechanical testing: tensile, impact, and hardness
- Types of failures: ductile vs. brittle fracture, temperature effects
- Analytical techniques: visual fracture examination, fractography, microscopy
- Industrial failure case studies
Day 2 – Damage Mechanisms and Failure Interpretation I
- Stress concentration effects
- Fracture mechanics fundamentals
- Fatigue and creep under high temperatures
- Thermal expansion and deflection analysis
- Practical worked examples
Day 3 – Damage Mechanisms and Failure Interpretation II
- Wear, galling, and fretting
- Corrosion types, damage mechanisms, and mitigation
- Equipment and piping vibration analysis
- Vibration condition monitoring
- Technical problem-solving and decision-making approaches
Day 4 – Equipment Failure Case Studies
- Pressure vessels and life extension strategies
- Heat exchangers, pumps, compressors, and mechanical seals
- Bearings, pipes, and repair techniques
- Practical examples of failure assessment
Day 5 – Inspection, Testing, and Condition Assessment
- Non-destructive testing (NDT) methods and techniques
- Inspection of process equipment
- Remaining life calculations and assessments
- Relevant inspection codes (e.g., API 570)
- Course summary and wrap-up
Certificates