UNDERSTANDING AND PREVENTING PROCESS EQUIPMENT FAILURES

Objective:

• Understand and predict degradation mechanisms that affect process equipment fitness for service and may lead to significant failures
• Recognize the interdependence of equipment design, operation, and maintenance in achieving mechanical integrity
• Develop knowledge of major mechanical failure mechanisms, including fracture, fatigue, creep, and corrosion
• Understand the fundamental concepts of inspection methods and Non-Destructive Testing (NDT) techniques
• Apply effective failure mitigation strategies to improve equipment reliability and safety
• Evaluate equipment condition and support informed maintenance and integrity management decisions

Content:

Materials Testing and Failure Mechanisms

• Course objectives and overview
• Materials testing methods: tensile, impact, and hardness testing
• Understanding failure types: ductile and brittle fracture
• Effects of temperature on material performance
• Analytical tools for failure investigation
• Visual examination of fracture surfaces
• Fractography and microscopy techniques
• Industrial failure examples and root causes

Damage Assessment and Failure Interpretation I

• Understanding stress concentration effects
• Principles of fracture mechanics
• Fatigue failure mechanisms
• High-temperature creep and material degradation
• Thermal expansion and equipment deflection
• Practical worked examples and failure analysis applications

Damage Assessment and Failure Interpretation II

• Wear, galling, and fretting damage mechanisms
• Principles and types of corrosion damage
• Corrosion prevention and mitigation strategies
• Equipment and piping vibration causes
• Vibration condition monitoring techniques
• Technical problem-solving and decision-making approaches

Equipment Failure Analysis and Case Studies

• Pressure vessel failures and life extension strategies
• Heat exchanger failure mechanisms
• Pump and compressor failure analysis
• Mechanical seal and O-ring failure investigation
• Bearing failure causes and prevention
• Piping failures and repair techniques

Inspection, Testing and Condition Assessment

• Overview of Non-Destructive Testing (NDT) methods and techniques
• Inspection practices for process equipment
• Remaining life assessment calculations
• Application of inspection standards and codes, including API 570
• Equipment condition assessment principles
• Course review, summary, and practical application

For Whom:

• Engineers involved in mechanical equipment design, fabrication, operation, and maintenance
• Operations, Technical Services, and Maintenance Professionals in processing industries
• Professionals responsible for equipment inspection, reliability, and repair activities
• Engineers seeking practical knowledge of structural integrity evaluation
• Project and Asset Managers responsible for equipment lifecycle management
• Consultants involved in plant expansion, retrofitting, and technology implementation projects