Course Content – SynGas Plants – Preventing Fixed Equipment Failures

Course Content – SynGas Plants – Preventing Fixed Equipment Failures


Venue & Time:
Centre for Advanced & Professional Education (CAPE)
Universiti Teknologi PETRONAS (UTP)
Level 8, Permata Sapura, Kuala Lumpur City Centre, 50088 Kuala Lumpur

Accepts in-person only

8:00 AM – 5:00 PM Malaysia Time (UTC+8)
Sections Date Location PDH Focus Cost Register
1 – 5 July 22 – 26, 2024 Kuala Lumpur​, Malaysia 40 hrs. SynGas Plants, Preventing Fixed Equipment Failures FULL USD 4,500
1, 2 ,3 only July 22 – 24, 2024 Kuala Lumpur​, Malaysia 24 hrs. Ammonia, Methanol Plants USD 2,700


One of the biggest concerns for owners and operators of syngas plants, is a loss of primary containment event, which brings with it the potential for personnel injury, significant equipment damage, and plant downtime.

Ultimately, all equipment failures are preventable, so why do fixed equipment failures still occur? Basically, equipment failures occur because there are gaps in a plant’s equipment ‘failure prevention controls’. Controls are what manufacturing facilities put into place to ensure continued safe and reliable operation of plant.

For example: Plant A suffered an on-stream failure of a catalyst tube. What was the root cause and what remedial actions should be implemented to ensure this doesn’t happen again?

  • Design and Construction: Were there gaps in the original manufacturing specification / QAQC during manufacture?
  • Process Operating Controls: How well balanced is your steam methane reformer, do you have some tubes running much hotter than others?
  • Maintenance Controls: Is the tube support system effectively maintained?
  • Inspection Controls: Why did your tube inspection program not pick up the damaged tube prior to failure? How effective is your remnant life assessment program?
Schedule Outline:

This course offers a unique opportunity to tailor your experience by attending only the sections that are most relevant to your training needs. Below, you’ll find the full outline for each day, along with the course schedule grouped into plant specific sections, to help you identify which sections are best suited for you and your team to attend.

*A 10% discount will be offered to all registrants attending all 5 days. Group discounts apply as normal.

  • Section 1 – 5: SynGas Plants, Preventing Fixed Equipment Failures FULL COURSE
  • Section 1 & 2 Only: Steam Methane Reformers & Hydrogen Plants Focus
  • Section 1, 2, 3 Only: Ammonia & Methanol Plants Focus
  • Section 4 & 5 Only: Metallurgy & Damage Mechanisms Focus
  • Section 5 Only: Welding Tech & SynGas Equipment Repair Focus
Print / PDF
Section 1 – Monday

  • Introductions & Review Course Outline
  • A1 SMR’s – Process Function & Design
  • A2 SMR’s – Start-up, Shut-down, Controls & Heat Balancing
  • A3 SMR’s – Catalyst Management
  • M3 Elevated Temperature Damage Mechanisms
  • M3 Elevated Temperature Damage Mechanisms
  • M3 Elevated Temperature Damage Mechanisms
  • A4a SMR’s – Radiant Inlet System
Section 2 – Tuesday

  • A4b SMR’s – Catalyst Tubes
  • A4c SMR’s – Radiant Outlet System
  • A4d SMR’s – Transfer Lines / Cold Collectors
  • A4e SMR’s – Convection Section
  • A6 Process Waste Heat Boilers
  • A6 Process Waste Heat Boilers
  • A7 Shifted Gas Loop
Section 3 – Wednesday

  • A8 CO2 Removal Loop (hydrogen, ammonia, methanol)
  • A5 Secondary Reformer & refractory management
  • A9 Methanation Loop
  • A10 Ammonia Conversion Loop
  • A12 Refrigeration & Ammonia Storage Loop
Section 4 – Thursday

  • M1 Basic Metallurgy Principles – Steels & Alloy Steels
  • M2 Basic Metallurgy Principles – Austenitic Materials
  • M4 Corrosion Damage Mechanisms
  • M4 Corrosion Damage Mechanisms
Section 5 – Friday

  • M5 Mechanical Damage Mechanisms
  • M6 Welding Technology & Equipment Repair
  • M6 Welding Technology & Equipment Repair
Who Should Attend:

This highly interactive and hands-on training caters for inexperienced as well as experienced engineers and inspectors. This program is very beneficial to Fixed Equipment Reliability Engineers, Process Engineers, Materials Engineers, Mechanical Engineers, Inspectors and Design / Construction Project Engineers (QA/QC) who work on or support Syn Gas Manufacturing Plants.

Benefit to participants and their facilities:

This experiential training program will provide participants with a much broader and deeper working knowledge of:

  • Materials and damage mechanisms applicable to your syngas plant, including potential for and consequence of equipment failure.
  • What damage mechanisms should be included in your sites RBI program to ensure effectiveness of inspections and condition assessments.
  • What critical process controls need to form part of your plant’s integrity operating windows program.
  • What gaps may be present in your current fixed equipment failure prevention controls.
  • What equipment may be approaching end of life and what actions would be needed to quantify remnant life.
  • The importance of linking damage mechanisms with manufacturing specifications to ensure equipment does not fail from design and construction gaps.
  • Equipment integrity focused operation of critical plant equipment such as steam methane reformers, process waste heat boilers, thick walled pressure vessels, cyclic equipment such as pressure swing absorbers and so on.
David Keen
David Keen is a qualified Metallurgist with over 46yrs domestic and international experience in Syngas manufacturing facilities. David is a Subject Matter Expert (SME) on fixed equipment integrity management and has in recent years downloaded this knowledge into a series of training modules focused on preventing equipment failures through experiential learning and team problem solving sessions.

He has held various positions including Global Company Chief Engineer, VP Global Reliability & Risk, Company Engineer Fixed Equipment, Reliability Manager, Operations Manager, Maintenance Manager, T/A Manager and Plant Metallurgist. David has worked as a consultant to Hydrogen, Ammonia and Methanol plants in 12 countries globally. He has been involved in implementing RBI programs, IOW programs, auditing fixed equipment management, completion of failure investigations, root cause analyses, fixed equipment repairs and design and construction of new fixed equipment.

David has worked on 33 steam methane reformers and is a recognized subject matter expert in the integrity management of SMRs.

Becht offers the following discounts on Public Training:

The highest applicable discount will be applied; discounts are not additive.

  1. Early Registration – A 10% discount is to be provided when you register 30 days before the start date of the training.
  2. Group Rate – A group discount is applied when you send three or more people from your organization to the same course and provide a single payment.
  3. No. of Registrants Discount/Person
    3 10%
    4 – 6 20%
    7 and up 25%
  4. Yearly Commitment Discount – A 25% discount when you prepay for a minimum of 10 participants from your organization to any of the courses in the same year.

Cancellation Policy:
Full refunds or course transfers are available 4 weeks prior to the class start date. Cancellations 2-4 weeks out are eligible for course transfers or a refund of 60% of the registration fee. Cancellations within 2 weeks of the class will not be eligible for a refund. For any inquiries, please email

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