Training Certificate

Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees.

Course Introduction

Although Carbon steel has been the first and widely used material in oil fields and other industry, today close to a hundred alloys and metals are used in various extracting and refining activities. Yet failures do happen, some of them leading to disastrous ends resulting in loss of assets and lives. . Plant and machinery designed with carbon steel material some three decades ago are now operating in the most demanding and aggressive conditions. Therefore Plant and machinery reliability has become a key issue in the interest of personnel safety, while total productivity and maintenance is a matter of equal importance Do metals fail due to normal out only or do they suffer from stress, fatigue and have ageing problems as humans? What are the tools available to test the reliability of old and new material? What are codes and standards for correct and economical material selection?

Course Objective

This course is designed to discuss in detail all physical and chemical properties of materials and testing methods specially of carbon steel; the benefits of heat treatment; The usage of   other non ferrous  and non metallic material; and an over view of  API and ASME Codes and standards

Suitable For

A condensed course on metallurgy for all plant inspectors, process engineers, and maintenance engineers  who are interested in knowing why some components fail more often than expected- A Corrosion awareness- For plant operators/ engineers who are interested in learning about fitness for service of plant  and equipment- For Managers interested in health safety and environment in case of unintended plant failure-for Managers interested in MRO and plant maintenance cost to know about alternative material.

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

Course Content

COURSE OUTLINE

Day 1 The origin of Metallurgy

• History
• The Stone Age and the discovery of metals
• Metals and non- metals
• Ferrous and non ferrous
• The art and science of metallurgy
• Steel making ancient and modern
• Discovery of other metals
• Periodic classification

• Physical and Chemical properties

• • Atomic model
  • Crystal structure and grain boundaries
  • Mechanical properties
  • Demerits of carbon steel
  • Discovery of stainless steel

Day 2 Carbon steel and its properties

• Fe- C diagram

• TTT  diagram of low alloy
• Heat treatment
• Microstructure and properties

• • Heat treatment as a chemical process

• • • Nitriding
    • Carbonizing
    • Flame hardening
    • Ausforming
    • Induction hardening
    • PWHT

• • • Stainless steel alloying material
    • Nickel and Chromium
    • Trace elements
    • High alloys

Day 3. Corrosion Effects & Equipment used in oil and gas extraction process

• The corrosive environment
• Corrosion Properties of Metals & Alloys
• Corrosion effects in offshore environment
• Reactors and pressure vessels
• Boilers and heat exchangers
• Heaters and dryers
• Separators
• Valves and compressors
• Pipes and storage vessels

Metals and alloys used in them – failures and causes

Selection of material for Offshore Production Fields

Selection of materials in offshore environment

Selection of materials for wellheads

Monitoring of corrosion & Non- Destructive Testing of (NDT) of Offshore Equipment

Day 4.  Selection of material using codes and standards

• Brief over view of  ASME and API  and NACE standards
  • Modern lab techniques for testing
  • Microstructure and failure analysis
  • Inspection and acceptance of new material
  • Specifications and standards

• Inspection procedures
  • • Laboratory and site
    • Destructive and non destructive
    • Physical and electrochemical

Day 5.Non ferrous metals and non metals in gas and oil industry

• Properties and application of
  • • Copper and alloys,
    • Titanium,
    • Aluminum,
    • Nickel and alloys

• Non- metallic’s
  • • Ceramics
    • Fiberglass
    • Polymers and plastics
    • And their various applications

• Design considerations

• • • Welding
    • Joining

• Safety, health, and environment.

Case Studies, Last Day Review, Discussions & Pre & Post Assessments will be carried out.