Process Equipment and Piping Systems: Design, Application, Failure Prevention, and Maintenance

Introduction:

The efficient operation of various industries, particularly in the oil and gas sector, relies heavily on process equipment and piping systems. Ensuring long-lasting performance is crucial, as the design, prevention, and repair of process equipment and piping define their operational effectiveness.

These systems often operate under severe conditions, making knowledge of damage mechanisms essential to prevent catastrophic failures. Predictive maintenance and risk-based inspections are critical to avoiding breakdowns and maintaining the quality, reliability, and efficiency of facilities.

This course on process equipment and piping design for prevention and repair highlights the importance of inspecting systems for damage and impact, ensuring infrastructure support, and maintaining normal operations. With numerous pieces of equipment and extensive piping layouts, a risk-based approach prioritizes critical systems based on damage effects and failure risks.

Participants will gain valuable knowledge and refine their technical skills, enhancing their overall experience in the course.

Objectives:

At the end of this comprehensive course, participants will:

• Understand the crucial role of maintaining mechanical integrity in process piping and equipment.
• Assess, predict, identify, and manage time-dependent degradation mechanisms.
• Acquire skills in damage and failure analysis for effective prevention and diagnosis.

Training Methodology:

• Interactive discussions
• Field surveys
• Field study
• Individual work
• Manipulative techniques
• Site visits
• Focus groups
• Discussion and presentation

Course Outline:

Unit 1: Fundamentals of Failure

• Wear and failure types
• Imperfections and defects
• Corrosion processes
• Modes of failure
• Fatigue
• Creep and thermal fatigue
• Stress corrosion cracking
• Materials: Carbon steel, alloy steels, nickel, titanium, aluminum, copper, plastic pipes, and cladding
• Material selection and lifecycle cost evaluation

Unit 2: Design Against Failure

• Failure causes: design, operation, maintenance
• Properties and limitations of materials and components
• Characteristics of steel pipes, twisted metals, and fittings
• Design considerations for pressure vessels, piping systems, and liquid storage tanks
• Mechanistic studies of process equipment damage

Unit 3: Process Equipment Failures

• Failures in pressure vessels, pipes, and boilers
• Material erosion and case studies
• Vibration issues: Mechanical, flow force, and induced resonance
• Plumbing hydraulic actions and water hammer
• Pipe supports, restraints, and the effect of wind
• Industry practices to prevent failures

Unit 4: Inspection, Assessment, and Maintenance of Process Equipment

• Inspection strategies, plans, and procedures (e.g., API 580)
• Risk-Based Inspection (RBI) development
• Fitness for service (API 579)
• Non-Destructive Testing (NDT) methods
• Defect probability and damage identification
• Smart pigs and cleaning methods
• Pipeline systems operation and maintenance

Unit 5: Operational Safety and Maintenance

• Maintenance strategies to extend service life and efficiency
• Repairs and modifications of pressure equipment and piping systems
• Procedures for rerating piping and pressure vessels
• Impact assessment of failures
• Methods for failure analysis and assessing potential effects