TRAINING.

Overview

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

• Gain 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 the design, operation, and maintenance of pressure equipment
• Understand the concepts of inspection and application of NDT methods
• Perform fitness for service analysis to calculate the 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 a significant role in most accidents that occur in the process industry. Failures can have serious consequences, resulting in leakages, toxic releases, fires, or explosions. They can 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 a 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, and 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
• Methods: Hazard and Operability (HAZOP) and Layers of Protection (LOPA
• Studies with 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 the 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 Petrochemical, Process and Power, and Generation Industries. Technical Personnel in charge of Plant Operation, Maintenance and Reliability of Pressure Equipment and Rotating Machinery

Please note: You can check other time zones here.

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

Instructor

Mike Ivanovic, Ph.D.

Dr. Mike Ivanovic is the President of UBAMIP Consulting and a former Adjunct Associate Professor with over 30 years of experience in thermal engineering. After working in the consulting group of ANSYS Canada Ltd., he now runs the private consulting company UBAMIP Consulting, dealing with analysis and problem-solving in the operation of vital stationary and rotating equipment in the process and petrochemical industry. Mike has also been active in providing training technical courses of various levels of complexity for professionals in the industry in Canada, the USA and overseas.

His expertise, among others, includes the design, operation and maintenance of various types of storage tanks, pressure vessels, piping systems, and pumps and compressors. The focus of the consulting projects has been on risk assessment during operation and maintenance activities, as well as equipment failure analysis and accident prevention technologies based on inspection results and fitness for service studies.