Pressure Equipment Engineering Fundamentals and Damage Mechanisms
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Description
This course provides students essential knowledge for managing process equipment in a plant environment. Design and post-construction considerations for pressure vessels, heat exchangers, fired heaters, boilers, piping, and tanks are presented with an applied emphasis. For example, rather than focusing on the many design rules in Section VIII Division 1, students learn to check flange ratings as the first step of a rerate. Practical information is brought to life with case-studies, examples, and practice problems throughout the course, taught by expert instructors with many combined decades of plant experience and learnings.
Who Should Attend
This course is primarily intended for new mechanical engineers involved with inspection, repair, and alteration of pressure equipment. This course may also be beneficial for project engineers needing an introduction to fixed equipment, experienced personnel wishing to update their knowledge and experienced inspectors.
Learning Roadmap
- Jurisdictions
- – State regulations and NBIC vs. the ASME B&PV Code
- – Code states and non-code states– RAGAGEP
- Design codes
- – Design responsibility
- – Company standards
- In-Service Codes and Standards
- – FFS vs. rerating
- – API 510 and API 570
- – Design guidelines in conflict with design codes
- Codes & standards – basis and margin
- – ASME VIII-1
- – ASME VIII-2 and ASME I
- – Code cases
- Loads
- – Pressure and temperature
- – System loads
- – Wind and Seismic
- – External pressure/vacuum
- – Thermal Stress
- Special services
- – Creep
- – Fatigue
- – Hydrogen
- – Cryogenic
- Supports and internals
- – Horizontal vessels
- – Vertical vessels
- – Internal support and allowable
- Rerates
- – Flanges ratings
- – Carbon steel and temperature rerates
- – Pressure rerates
- – Legacy materials
- Undocumented equipment
- Specifying new equipment
- Piping
- – Codes and standards
- – Conditions beyond design
- – Supports
- – Piping vs. pipelines
- – Vibration mitigation
- Heat exchangers
- – ASME VIII-1 vs TEMA
- – Common design details
- – Design rules of thumb
- – Troubleshooting
- – Vibration
- Fired Heaters
- – Design and in-service codes
- – Tube rupture
- – Fired boilers and ASME I
- – Unfired steam generators and ASME VIII vs. ASME I
- ASME VIII-1 Mandatory Appendix 2 vs. ASME PCC-1
- ASME PCC-1 and integrity program basics
- Selecting bolting
- Selecting gaskets
- Common problems and solutions
- Codes and standards
- Common damage
- Inspection
- Reliability basics (MI programs, RBI)
- Repairs and ASME PCC-2
- API 510 and API 570
- Nondestructive Examination (NDE)
- Refractory lined equipment
- Fitness-for-Service
- – Common damage mechanisms
- – Levels
- – Level 3 triggers
- – Required information
- – Data needs and collection
- – Brittle fracture (screening)
- – Hot spots
- – Introduction to fracture and creep
- Developing maintenance packages
- Checking 3rd party work
- Introduction, Goals, Outcomes
- Intro. to Metallurgy and Properties, Heat Treatment
- Crude/Vac Unit Overview
- – Desalter and crude overhead corrosion, incl. vac tower organic acid issues
- – Sulfidation (Organic) and Naphthenic Acid corrosion
- – Ammonium Cl and HCl Corrosion
- – Permanently installed corrosion probes
- Naphtha HT and Cat Reformer Overview
- – HTHA
- – Heater tube oxidation and creep
- Diesel HT/Hydrocracker Overview
- – High temperature H2/H2S corrosion
- – NH3BS corrosion (sour water) and REAC’s
- – Temper Embrittlement and Minimum Pressurization
- Temperature
- – PAUT inspection
- – Wet H2S Cracking WFMT and Surface Eddy Current and FFS
- of wet H2S damaged equipment– Cl SCC and PASCC and
- downtime protection (soda ash washing), low pt drains,
- caustic SCC
- FCC Overview
- – Erosion
- – Carbonate SCC and wet H2S cracking and AUT
- – CUI
- Coker
- – Thermal Fatigue– Carburization
- Amine and Sulfur Units
- – Amine SCC
- – Amine corrosion
- Hydrogen Plant
- HF Alkylation
- Sulfuric Acid Alkylation
- NDE
Instructors
Everett Chatham has over 20 years of experience with deep bolted joint and mechanical expertise across plant equipment in the refining, petrochemical, and chemical industries from his many years at Shell, Lyondell Houston Refinery, and Dow Chemicals. Everett developed scope of work for repairs and alterations to pressure equipment including vessels, piping, tanks and bolted joints analysis. He holds a BS degree in Science Mechanical Engineering from Texas A&M University.
Nathan Barkley, P.E.
Nathan Barkley has nearly 15 years of experience with mechanical design and analysis of pressure vessels and heat exchangers in the refining and chemical industries. Prior to joining Becht, he was the Lead Design Engineer at a world-class fabrication company building ASME Section VIII, Division 1 and Division 2 equipment. He has extensive experience with ASME and API codes and standards for new and post construction. In addition to basic pressure vessel design per Section VIII of the ASME Boiler and Pressure Vessel Code, his experience includes design by analysis for the failure modes of Division 2 Part 5, design certification, fitness for service, rerating, alteration, repairs, and inspection.Mr. Barkley is actively involved in ASME as a voting member or contributor to the Section VIII Subgroup committees on General Requirements, Design, and High Pressure Vessels. He also holds leadership positions within the ASME Pressure Vessels and Piping Conference and has published several peer reviewed conference papers on pressure vessel design. Mr. Barkley holds a MS degree in Mechanical Engineering and certificate in Engineering Mechanics from Missouri University of Science and Technology and a BS degree in Mechanical Engineering from the University of Mississippi. He is a licensed Professional Engineer in the state of Texas and holds an inspector certification in API 510.
Nasser Sheikhi is refinery mechanical, Integrity Expert with broad experience in metallurgy, corrosion, welding, risk-based inspection and fitness-for-service. During his 41 years with BP, he has held several positions in both refineries and central engineering organizations. His work in the refineries involved site metallurgist & Corrosion technical authority, TAR inspection lead and inspection & reliability superintendent, and held corporate metallurgy & corrosion advisor position. During his corporate role, his main responsibility was writing corporate risk-based inspection documents. He was the main SME to perform unit DMRs, reviewing corrosion control documents (CCD) and auditing other RBI related work. During his role as advisor, he was involved with various major projects and refinery reliability issues. He also audited numerous major equipment fabrications.Nasser has been active member of API and NACE STG 34, STG 39, and TEG 205X. Nasser majored dual degree in both BS Metallurgical Engineering and Chemical Engineering from the University of Minnesota.
