Course Catalogue.

After participating in this course, you will be able to:

• Understand fundamental failure modes such as corrosion, fatigue, rupture, and thermal shock and how they affect various types of equipment.
• Accurately predict degradation mechanisms to mitigate component failures and improve equipment reliability.
• Analyze the critical relationship between design, operation, and maintenance for extending the life of pressure equipment.
• Apply advanced non-destructive testing (NDT) methods to diagnose potential failure points.
• Perform comprehensive fitness-for-service evaluations to estimate the remaining lifespan of critical equipment.

Description
Failures in pressure vessels, piping, and rotating machinery represent a significant risk to process industries, where equipment performance and integrity are vital. The consequences of failure can range from costly shutdowns to dangerous accidents, including fires, toxic releases, or equipment damage. Understanding the degradation mechanisms, including fatigue, corrosion, and thermal stress, is critical for maintaining the reliability of pressure equipment and rotating systems, such as pumps and turbines.

Participants in this course will gain insight into the causes of failures originating from improper design, installation, operation, and maintenance practices. Key topics include the analysis of failure modes, hazard and operability (HAZOP) assessments, and Failure Mode and Effect Analysis (FMEA). You will also explore post-accident investigation strategies, root cause analysis (RCA), and non-destructive testing (NDT) to identify and prevent equipment malfunctions.

The course will emphasize practical applications through real-life case studies and workshops. Additionally, participants will be trained to perform fitness-for-service analyses and calculate equipment's remaining life, ensuring that safety, performance, and maintenance schedules are aligned to extend the operational life of critical plant assets.

Who Should Attend
This course is designed for mechanical and process engineers, maintenance engineers, plant technologists, and inspectors working in the petrochemical, power generation, and process industries. Technical personnel responsible for the reliability, maintenance, and operation of pressure equipment and rotating machinery will benefit greatly.

It is also suitable for safety management, failure analysis, and condition monitoring professionals who want to deepen their expertise in failure prevention and repair strategies. Engineering managers and supervisors overseeing maintenance activities in industrial plants will find the content valuable for enhancing operational safety and equipment longevity.

Course Syllabus

Day 1:  Failure Modes & Mechanisms of Process Equipment

• Material Degradation Processes: Effect of Ageing
• Modes of Equipment Failures
• Causes of Equipment Failures: Design, Operation, Maintenance
• Failures in Pressure Vessels, Storage Tanks, Piping Systems
• Failures in Rotating Machinery
• Consequences of Failures in Industry
• Workshop: Case Studies, Examples and Solutions

Day 2: Diagnostics of Equipment Failures: Root Cause Analysis

• Need for Failure Analysis: Fault Tree Analysis (FTA)
• Methods: Hazard and Operability (HAZOP) and Layers of Protection (LOPA)
• FMEA - Failure Mode Effects Analysis and LOPA
• Diagnostics of Fatigue, Cracks and Ruptures
• Analysis of Failure Data using the Weibull Distribution Method
• Root Cause Analysis (RCA) of Failures in Operation
• Risk Management and Mitigation Techniques - ALARP Criteria
• Industry Practices for Failure Prevention
• Workshop: Case Studies, Examples and Solutions

Day 3: Inspection, Monitoring, and Fitness for Service

• Inspection Strategies, Scope and Procedures
• Risk-Based Inspection (RBI API 580)
• NDT - Non-Destructive Testing Techniques
• Fitness for Service Analysis (FFS API 579)
• Calculation of the Remaining Life of Equipment
• Rotating Machinery Condition Monitoring and Vibration Analysis
• Workshop: Case Studies, Examples and Solutions

Day 4: Maintenance and Repair Management

• Computerized Maintenance Management System (CMMS)
• ASME and API Standards for Maintenance and Repair of Equipment
• Repair and Alteration of Pressure Equipment: Vessels, Tanks and Piping
• Decision Making on Equipment Repair and Replacement
• Maintenance and Troubleshooting of Rotating Equipment
• Workshop: Case Studies, Examples and Solutions

Concluding Remarks and Final Adjournment