#1520 - Maintenance of Process Plant Equipment
Course Objective
Upon completion of this course, attendees will be able to:
- Apply the requirements of the relevant industry standards and practices to the maintenance of pressure vessels, heat exchangers, piping systems, and aboveground atmospheric storage tanks.
- Develop inspection and maintenance programs for process plant equipment and piping systems.
- Prepare appropriate details for repairs and alterations to process plant equipment and piping systems.
Who Should Attend?
Engineers, managers, and others who are responsible for the inspection and maintenance of pressure vessels, heat exchangers, aboveground atmospheric storage tanks, and piping systems. Engineers who are responsible for fitness-for-service evaluations. Course attendees should already have a good fundamental understanding of the mechanical design requirements for these equipment items.
Course Description
Pressure vessels, heat exchangers, aboveground atmospheric storage tanks, and piping systems typically represent over half the capital investment in a process plant. Mechanical engineers at end-user locations or in central engineering organizations are often responsible for the evaluation and maintenance of all these items, not just one or two.
This course is unique in that it discusses all these items in a single course. This material is covered by concentrating only on the most commonly applied topics in each case, rather than attempting to discuss everything. Therefore, attendees receive broad, practical training in a single course rather than having to attend multiple courses. This maximizes their learning in a relatively short time. Those that require additional training for a particular item or topic may take a specialized course that covers it in more detail.
The material presented demonstrates some concepts that are not always shown or described in textbooks. The course emphasis is on developing a practical understanding of the maintenance requirements for fixed equipment and piping systems in process plant applications. Sample problems and participant exercises are included throughout the course to illustrate the concepts discussed and provide the attendees with practice in applying them.
Course Outline
- Overview
- Deterioration Mechanisms
- Fitness-for-Service Assessments
- Pressure Vessel Maintenance
- Pressure Vessel Integrity Program
- Overall Risk Assessment
- Inspection Plan
- Fitness-for-Service Assessments
- Overview of API RP 579 requirements
- Data Requirements
- Assessment Methods and Acceptance Criteria
- API 510 Requirements
- Pressure Vessel Inspection Practices
- Causes of Vessel Deterioration
- Inspection Intervals
- Corrosion Rate Determination
- Evaluating Corroded Pressure Vessels for Continued Operation
- Determining Minimum Actual Thickness
- Acceptability of Corroded Area
- Brittle Fracture Assessment
- Fracture Toughness Determination
- Brittle Fracture Evaluation of Existing Equipment
- Details for Welded Repairs and Alterations
- Classification of Repairs and Alterations
- Welding and Design Requirements
- Defect Repairs
- Rerating Pressure Vessels
- Changes to Original Design Conditions
- Hydrotest Requirements
- Glossary
- Heat Exchanger Maintenance
- Evaluating the suitability of corroded components
- Typical maintenance and inspection procedures
- Locating leaks
- Leak repairs
- Retubing considerations
- Typical cleaning methods
- Tube inspection techniques
- Rerating exchangers
- Piping System Maintenance
- Piping Materials and Modes of Failure
- Materials Considerations
- Corrosion Rate and Remaining Life Calculation
- Cracking Mechanisms in Piping
- Piping Deterioration
- Piping Inspection and Evaluation
- API 570 Requirements
- Piping Inspection Planning and Data Analysis
- Inspection Techniques for Piping and Components
- Piping Retirement
- Piping System Repair, Alteration, Rerating, and Pressure Testing
- Valve Repair and Maintenance
- API 570 Piping Repair, Alterations, Rerating, and Testing Requirement Piping System Repair
- Piping System Alterations and Rerating
- Pressure Testing After Repairs or Alteration
- Flange Joint Assembly and Bolt Up Procedure
- Introduction
- Establish Flange Joint Categories
- Identify and List Flange Joints in Critical Services
- Determine Required Bolt Type and Material
- Select Bolt Tightening Method
- Develop Flange Joint Assembly and Bolt Up Procedures
- Procedure Qualification
- Crew Qualification
- Hot Bolting
- Additional Leakage Control Procedures
- Guidelines for Hot Tapping (Pressure Tapping)
- Necessary Conditions for Performing a Hot Tap
- Hot Tap Design Considerations
- Selecting the Hot Tap Site
- Installation
- Inspection
- Pressure Tests Before Cutting Pipe
- Hot Tap Operations
- Special Safety Considerations
- Hot Tap Machines
- Appendices
- Design Procedure for Designing Welded Full Encirclement Repairs with End Plates
- Design Procedure for a Welded Full Encirclement Sleeve
- Design Procedure for a Fillet-Welded Lap Patch
- Design Procedure for Welded Partial Leak Containment Box
- Glossary
- Aboveground Storage Tank Maintenance
- Introduction
- Scope of API 653
- Definitions
- Starting an API 653 Compliance Program
- Tank Inspection
- Objectives
- Prioritization
- Inspection Frequencies
- Record Keeping
- Inspector Qualifications
- Tank Component Evaluation
- Shell
- Bottom
- Roof
- Foundation
- Shell and Bottom Settlement
- Tank Repair and Alteration
- General Considerations
- Material Considerations
- Removal, Repair, and Replacement of Shell Plate Material
- Repair, Addition, Replacement, and Alteration of Shell Penetrations
- Repair of Tank Bottoms
- Tank Roof Repair
- Dismantling and Reconstruction
- Dismantling Methods
- Reconstruction
- Dimensional Tolerances
- Examination and Testing
- General
- Welding Inspection
- Hydrostatic Testing
Course Duration – 4-5 Days