Day 1 – Engineering Materials – Types and Properties

Engineering Materials I – Overview

Metals – Ferrous and non-ferrous
Carbon steel
Alloying elements added to iron base – carbon, manganese, and silicon
Effect of alloying elements on end properties and on fabrication processes
Impurities and their effect – sulfur, phosphorus
Alloy steel
Effects of alloying elements
Stainless steels
Specialty alloys
Corrosion resistant alloys
High temperature alloys
Erosion resistant alloys
Engineering Materials II

Refractory materials – Types and applications – Examples: Titanium and zirconium
Clad Materials – Types; production methods; and typical applications
Composite materials – Classes, types and applications
Non-Metallic materials – Plastics, ceramics
Surface engineered coatings/overlays – Types, specifications and applications
Organic coatings
Metallic coatings
Corrosion resistant cladding
Corrosion resistant / hard-surface welding
Thermal spray coatings
Plasma transferred arc (PTA) welded overlays
Metallurgy Basics

The structure of metals and alloys
Imperfections in metals and alloys
Chemical composition – Unified numbering system (UNS)
Physical properties – melting temperature, the thermal conductivity, electrical conductivity, the coefficient of thermal expansion, and density
Mechanical properties – Base metals, filler metal and completed welds
Tensile and yield strength, ductility, hardness and toughness
Heat treatment and effect on material properties
Material Forming and Fabrication

Forming and forging
Casting
Welding processes – main technologies and consumables currently used in industry
Weldability – Carbon equivalent; Shaeffler and WRC diagrams
Preheat and Post-Weld heat treatment (PWHT) – Code (B&PV and B31) rules
Weld imperfections (discontinuities) commonly encountered with welding processes
Overview of ASME B&PVC Section IX ‘Welding and Brazing Qualifications’

This Section contains rules relating to the qualification of welding and brazing procedures as required by other code sections for component manufacture
Welding procedure specification (WPS)
Procedure qualification record (PQR)
Welder performance qualification (WPQ)
Day 2 – Materials Selection and Application

Material Selection Process and Guidelines

Life cycle cost considerations
Factors in material selection in petroleum refineries- type of refinery; type of crude oil processed; service conditions in specific process unit/application, expected service life
Oxidation resistance – scale formation
Guidelines on the maximum temperature of use of carbon steel and alloy materials
Creep properties – The Larson-Miller parameter (LMP)
Fatigue properties – Fatigue design (S-N) curves
Materials Standards and Codes

ASME Boiler and Pressure Vessel and Piping Construction Codes
Allowable stresses
Constraints and limitations
P-Number identificat
ASTM – Some common material specifications for piping, plates, forgings and castings
Materials Standards and Codes (continued)

API RP 941 – Steels for hydrogen service at elevated temperatures and pressures in petroleum refineries and petrochemical plants
Oxidation resistance – scale formation
NACE MR0103 ‘Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments’
PIP (Process Industry Practices) Standards – Example: PIP Piping Material Specification 1CS2S01 Class 150, Carbon Steel, Socket Weld, 0.125 C.A. Process.
Fatigue properties – Fatigue design (S-N) curves
Overview of ASME B&PVC Section II ‘Materials Specifications’ – This Section compiles material specifications and material properties for materials used in the construction of ASME components. It contains four parts:
Part A-Ferrous Material Specifications
Part B-Nonferrous Material
Part C-Specifications for Welding Rods
Part D-Properties-(Customary)
Material Selection for Specific Equipment

Refineries and petrochemical plants
Power plants
Pressure vessels
Piping valves and fittings
Pumps
Day 3 – Degradation of Materials In-Service

Material Ageing and Degradation – Overview

Ageing is not about how old equipment is; it’s about knowledge of its condition, and how that is changing over time
Indicators or symptoms of ageing
Failure Modes and Mechanisms in Materials

Degradation processes – (e.g. corrosion, erosion)
Excessive elastic deformation – (e.g. buckling)
Fracture – (e.g. fatigue, brittle fracture)
Overview of API RP 571 Damage Mechanisms Affecting Fixed Equipment

This document provides background information on damage that can occur to equipment in the refining and other process industries. It covers over 60 damage mechanisms. It is also an excellent reference for inspection, operations, and maintenance personnel.
Metallurgical Failure Analysis

Overview
Case study
Positive Material Identification

Objectives and methodologies (e.g. X-Ray Fluorescence and Optical Emission Spectroscopy)
ASTM- E1916
Pipe Fabricator Institute PFI-ES42
API 578
MSS SP-137-2007
Material Test Reports
Day 4 – Inspection Strategies and Non-Destructive Examination Methods

Mechanical (Structural) Integrity – Overview

Definition, scope, and key elements – hardware and software issues, human factor, and asset manageme
Potential threats to technical integrity in a hazardous environment
Regulatory requirements – SH&E, OSHA, SEVESO II
Life cycle implications – design/operation/maintenance, management of change
Inspection Strategies and Methods

Real function of inspection
Planning and strategies
Inspection Strategies and Methods (continued)

Overview of API RP 580 and RBD 581 – Risk-Based Inspection
Overview of API RP 577 Welding Inspection and Metallurgy
Non-Destructive Examination (NDE) Methods and Their Application

Capability of the applicable inspection method vs. discontinuity
New developments in NDE methods
Overview of ASME B&PVC Section V ‘Nondestructive Examination’

This section contains requirements and methods for non-destructive examination referenced and required by other code sections.
Day 5 – Fitness-For-Service Evaluation

Introduction to Fracture Mechanics

Overview
Illustrative worked examples
Fitness-for-Service Assessment

Overview of API Std. 579-1/ASME FFS-1
Worked examples