PreDiCon Systems
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PreDiCon Systems
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SE03 Maintenance of Process Plant Equipment Introduction Pressure vessels, heat exchangers, aboveground atmospheric storage tanks, and piping systems typically represent over half the capital investment in a process plant. These fixed equipments and piping systems are subject to a number of damage mechanisms throughout their service life that could result in serious or even catastrophic failures. Effective inspection strategies and programmes are required to monitor the condition of these fixed equipment and piping systems, to assess their fitness for continued service, make repair/replace decisions, and develop appropriate cost-effective repair methods This course is structured to provide the delegates with the appropriate mix of technical fundamentals and practical best practices to maximize their learning. The material presented demonstrates some concepts that are not always shown or described in textbooks. The course emphasis is on developing a practical understanding of the inspection and maintenance requirements for fixed equipment and piping systems in process plant applications. Sample problems and participant exercises are included throughout the course to illustrate the concepts discussed and provide the delegates with practice in applying them.
Course Objective
Apply the
requirements of the relevant industry standards and practices to the inspection
and maintenance of pressure vessels, heat exchangers, piping systems, and
aboveground atmospheric storage tanks.
Training Methodology This course combines sound engineering, operation and maintenance principles, applicable standards and best industry practices for reliable and cost-effective inspection and maintenance of fixed process plant equipment. It also enforces the learnings with case studies and Question & Answer workshops to maximize the benefits to the participants. Actual major incidents from the instructor's own experience as well as industry experience will be reviewed in depth to enforce every topic and opportunities for applying the learnings will be identified. Participants will be provided with comprehensive course notes and copies of presentation material that will be very valuable for detailed study and future reference.
Organisational Impact Identification and assessment of active degradation mechanisms coupled with implementation of a Risk Based Inspection program and effective maintenance strategies and methods would result in significant measurable improvements in fixed process plant equipment including: improved plant integrity, reliability and availability with fewer failures; optimization of inspection frequencies; timely and cost effective maintenance; optimization of inspection and maintenance resources through the application of risk assessment methodologies ; and reduction in life cycle costs while complying with applicable standards.
Personal Impact Delegates will acquire the knowledge and skills necessary to understand the degradation mechanisms that fixed process plant equipment may be subjected to and to apply risk-based methodology effectively in their work thereby enhancing their competence and performance level and making additional value added contributions to their organizations. Delegates will extend their knowledge of the requirements and application of relevant sections of the ASME Boiler and Pressure Vessel Code and B31 Piping Codes, as well as relevant API Codes, standards, and Recommended Practices including 571, 510, 570, 653, 580, and 579 in process plant equipment and piping system design, operation, inspection repairs and alterations.
Competencies Emphasised Delegates will enhance their competencies in the following areas:
Who Should Attend? Engineers, supervisors, managers, and other technical personnel who are responsible for the inspection, fitness-for-service assessments and maintenance of pressure vessels, heat exchangers, aboveground atmospheric storage tanks, and piping systems. Course Outline · MODULE 1 -INTEGRITY AND RELIABILITY OF PROCESS PLANT EQUIPMENT o Mechanical integrity – Interdependence of design, operation and maintenance o Regulations, codes, standards, and recommended practices o Key aspects of process equipment design o Deterioration Mechanisms – Overview of API RP 571 o Examples of industrial failures o Inspection strategies o Fitness-for-Service Assessments
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Module 2 -Pressure Vessel INSPECTION AND Maintenance
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Pressure Vessel Integrity Program
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Fitness-for-Service Assessments o Pressure Vessel Inspection
+ Overview
of API 510 Requirements
+
Definitions
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Pressure Vessel Inspection Practices
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Evaluating Corroded Pressure Vessels for Continued Operation
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Brittle Fracture Assessment
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Details for Welded Repairs and Alterations
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Rerating Pressure Vessels
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Changes to Original Design Conditions
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Hydrostatic Test Requirements o Glossary
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MODULE 3 - Heat Exchanger Maintenance
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Evaluating the suitability of corroded components o Typical maintenance and inspection procedures
+ Damage
mechanisms; tubes vibration o Rerating exchangers
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Piping Inspection and Evaluation
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Module 4 - Piping Materials and Modes of Failure
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Piping System Repair, Alteration, Rerating, and Pressure Testing
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Flange Joint Assembly and Bolt Up Procedure
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Guidelines for Hot Tapping (Pressure Tapping)
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Appendices
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Glossary
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Aboveground Storage Tank Maintenance
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Introduction
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Tank Inspection
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Tank Component Evaluation
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Tank Repair and Alteration
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Dismantling and Reconstruction
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Examination and Testing
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