Course Overview:
The presented first document identifies its target audience as trainers and engineers with supervisory responsibilities in the sectors of refining and petrochemicals.
At page 5 the specific goals of the training programs are Amaka 0448 and Amaka 0430, which are to provide knowledge of main damage mechanisms related to fixed equipment in the two industries while enhancing safety, reliability and reducing liabilities.
This will help participants understand the basics of metallurgy, welding, and materials of construction within the refinery, and healing factors like engineers and inspectors that will assist damage detection and prevention.
The course further examines refining processes and related damage processes, and non-destructive testing of equipment’s. It targets engineers and inspectors in the refining and petrochemical industries towards improving hands-on experience on damage identification and prevention.
Course Objectives:
By the end of this course delegates will be able to:
- Improve safety, reliability, and minimize liability of fixed equipment by learning common damage mechanisms in the refining and petrochemical industry as covered in API 571 are the primary objectives
- Learn the roles of the engineer and inspector in identifying affected materials and equipment, critical factors, appearance of damage, prevention and mitigation, inspection and monitoring
- Be introduced to the concepts of service-induced deterioration and failure modes
- Gain a fundamental understanding of damage mechanisms in metals
- Have an overview of basic metallurgy applicable to refinery construction materials
- Describe common refining processes on the Process Flow Diagram level, highlighting where various damage mechanisms are usually observed
- Discuss typical NDE methods and their ability to detect and characterize equipment damage
- Fully discuss the damage mechanisms that are found in refineries covered by RP 571
- Go through examples of equipment damage and failures.
Who Should Attend?
These courses can be delivered either as open public training courses or in-house and typically involve additional study, assignments and assessments. Not only do these training courses prepare you for the qualification but they also focus on providing practical skills and techniques which are directly transferred to the workplace.
Course Outlines:
Introduction to Carbon and Alloy Steel MetallurgyIntroduction to Carbon and Alloy Steel Metallurgy
Introduction to Carbon and Alloy Steel Metallurgy
- Basic carbon steel metallurgy: using the Fe-Fe3C phase diagram in practical terms
- Basic alloy steel metallurgy for high and low temperature service
- Common heat treatments for carbon and alloy steels
Introduction to Stainless Steel Metallurgy
Introduction to Stainless Steel Metallurgy
- Types and classification of stainless steels
- General corrosion resistance of stainless steels (advantages and disadvantages)
- General introduction to the weld ability of stainless steels and affect welding on corrosion resistance
Base Metal and Filler Metal Specifications – ASME Section II Parts A and C
Base Metal and Filler Metal Specifications – ASME Section II Parts A and C
- Classification of steels – UNS, SAE, ASTM, ASME
- ASME SA-105, SA-53, SA-106, SA-333, SA-516, SA-240
- AWS/ASME classification of filler metals, SFA No., F No., and A No
- Material test reports and what they really mean
Welding Metallurgy of Carbon and Alloy Steels
Welding Metallurgy of Carbon and Alloy Steels
- Wildman and metallurgical heat affected zones using fundamental principles of welding metallurgy
- Use of carbon equivalence to predict weld ability
- Hydrogen assisted cracking related to welding (toe cracking, cold cracking, delayed cracking, HAZ cracking, and under bead cracking)
- Preheating and post weld heat treat in practical terms to avoid cracking, improve weld ability, and resist weld related failures
General Damage Mechanisms as Described in API 571
Mechanical and Metallurgical Failure Mechanisms
General Damage Mechanisms as Described in API 571
Mechanical and Metallurgical Failure Mechanisms
- Graphitization and Softening (Spheroidization)
- Temper Embrittlement
- Strain Aging
- 885°F Embrittlement
- Sigma Phase Embrittlement
- Brittle Fracture
- Creep/Stress Rupture
- Short Term Overheating—Stress Rupture
- Steam Blanketing
- Dissimilar Metal Weld (DMW) Cracking
- Thermal Shock
- Erosion/Erosion-Corrosion
- Cavitations
- Mechanical, Thermal and Vibration-Induced Fatigue
- Refractory Degradation
- Reheat Cracking
Uniform or Localized Loss of Thickness
Uniform or Localized Loss of Thickness
- Galvanic Corrosion, Atmospheric Corrosion
- Corrosion Under Insulation (CUI)
- Cooling Water Corrosion, Boiler Water Condensate Corrosion
- CO2 Corrosion
- Flue Gas Dew Point Corrosion
- Microbiologically Induced Corrosion (MIC)
- Soil Corrosion
- Caustic Corrosion
- Dealloying
- Graphitic Corrosion
High Temperature Corrosion, 400°F (204°C)
High Temperature Corrosion, 400°F (204°C)
- Oxidation, Suffixation, Carburization, Decarburization
- Metal Dusting, Fuel Ash Corrosion
- Nit riding
Environment-Assisted Cracking
Environment-Assisted Cracking
- Chloride Stress Corrosion Cracking (Cl-SCC)
- Corrosion Fatigue
- Caustic Stress Corrosion Cracking (Caustic Embrittlement)
- Ammonia Stress Corrosion Cracking
- Liquid Metal Embrittlement (LME)
- Hydrogen Embrittlement (HE)
Refining Industry Damage Mechanisms as Described in API 571
Uniform or Localized Loss in Thickness Phenomena
Refining Industry Damage Mechanisms as Described in API 571
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
Environment-Assisted Cracking
Environment-Assisted Cracking
- Polyphonic Acid Stress Corrosion Cracking (PASCC)
- Amine Stress Corrosion Cracking
- Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
- Hydrogen Stress Cracking—HF
- Carbonate Stress Corrosion Cracking
Other Mechanisms
Other Mechanisms
- High Temperature Hydrogen Attack (HTHA) and Titanium Hydrating