TRAINING.

Overview

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

• Gain a knowledge of various types of failure modes: corrosion, fatigue, crack, fracture, rupture, thermal shock, etc.
• Predict degradation mechanisms that lead to component failures
• Appreciate the link between design, operation, and maintenance
• Understand the concepts of inspection and application of NDT methods
• Perform fitness for service analysis to calculate remaining life of equipment
• Introduce risk mitigation techniques to avoid potential failures
• Analyse effects of vibration and rotor balancing for rotating machines

Description
Equipment failures play significant role in most accidents that occur in process industry which can have serious consequences, resulting in fire, explosion, and toxic release, etc. The failures occur both in stationary pressure equipment such as pressure vessels, storage tanks and piping systems, as well as rotating machinery, such as pumps, compressors, turbines. This equipment represents major portion of plant assets and their mechanical integrity, safety and reliability are essential for plant availability and performance.

This course will focus on common causes of failures that originate from errors in design, operation, maintenance as well as inadequate inspection and monitoring. The course will explain how to perform Failure Mode and Effect Analysis and other methods of Failure Analysis The course is designed to be very interactive with intensive involvement of participants in workshops and class discussions. Several real-life case studies will be presented and discussed

Course Outline

• Explanation of Modes of Failures of various types of equipment
• Importance of Design, Installation, Operation, and Maintenance
• Typical Failures of Pressure Equipment and Rotating Machinery
• Application of Failure Mode and Effect Analysis (FMEA)
• Root Cause Analysis (RCA) applied in Post-Accident Investigation
• Inspection Strategies and Procedures with NDT Techniques
• Fitness for Service Analysis (FFS API 579) and Calculation of Remaining Life of Equipment
• Failures of Rotating Machinery and Troubleshooting Techniques

Who Should Attend
Mechanical, and Process Engineers • Maintenance Engineers and Technicians, Plant Technologists and Inspectors in the Petro-Chemical, Process and Power, Generation Industries. Technical people in charge of Plant Operation, Maintenance and Reliability of Pressure Equipment and Rotating Machinery

Please note: You can check other time zones here.

Syllabus

Daily Schedule:
10:00   Session begins
12:00 Lunch
6:00   Adjournment

There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session. Lunch and refreshments are provided

Day-1:  Failure Modes & Mechanisms of Process Equipment

• Material Degradation Processes: Effect of Ageing
• Nature and 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)
• FMEA - Failure Mode Effects Analysis and LOPA
• Diagnostics of Fatigue, Cracks and Ruptures
• Analysis of Failure Data using 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 API580) and other Standards
• NDT - Non-Destructive Testing Techniques
• Fitness for Service Analysis (FFS API 579)
• Calculation of Remaining Life of Equipment
• Rotating Machinery Condition Monitoring and Vibration Analysis
• Workshop: Case Studies, Examples and Solutions

Day-4: Maintenance and Repair Management

• Management of Maintenance Resources (CMMS)
• Maintenance, Repair and Alteration of Pressure Equipment
• Equipment Repair and Replacement Decision Making
• Relevant Maintenance and Repair Standards: ASME, API,
• Maintenance and Troubleshooting of Rotating Equipment
• Workshop: Case Studies, Examples and Solutions

Concluding Remarks and Final Adjournment

Instructor

Dr. Mike Ivanovic is President of UBAMIP Consulting, and also a former Adjunct Associate Professor at U of Toronto.

After working in the consulting group of ANSYS Canada Ltd., he now runs the private consulting company UBAMIP Consulting in Waterloo.

Mike has been very active in providing training courses of various levels of complexity for professionals in industry in Canada, USA and overseas.

His area of professional expertise has been the analysis and problem solving in operation of pressure systems, specifically of stationary components such as pressure vessels, storage tanks and piping systems, together with rotating machinery, such as pumps, compressors and turbines, in the process and petrochemical industry.

Technical consulting projects also included design, operation and maintenance of various thermal engineering components, such as heat exchangers and industrial heaters.

The focus in most of the projects has been on the equipment optimization, combined with the risk assessment and failure prevention technologies based on fitness for service studies and remaining life analysis.