Objective

A new insight into metal /material behavior other than normal high temperature operation which is familiar to engineers/operators

Content

Day 1 Carbon steel, the old veteran

• Metallurgy of Carbon steel, the most widely used metal in oil and gas industry equipment’s- Basis for selection-physical, mechanical and metallurgical properties-Role of trace metals - effect of impurity and temperature-TTT diagram.
• Pre- service defects during- fabrication- storing-transport –installation and commissioning - flaws - defects and failures.
• In service defects- simple environmental conditions -

• Understanding corrosion- under ambient conditions and in presence of water

• Why do metals and materials fail?
• Why different materials show different failure patterns?
• The eight forms of material failure (corrosion)-Basic theory of corrosion
• Understanding cause of failure- from case studies and photographs
• Theory of corrosion made simple by experiments made by great people like Galvano, -Ohm’s law and Niels Bohr atomic theory

Day 2 Gas processing environment

• Types of Gas and oil resources- oil gas and water mixture and separation issues- Gas processing- phase issues and flow regimes- velocity and temperature factors in mixtures- corrosion in TOL and bottom of line-
• Types of environments in gas industry-aggressive-C02-H2S-amine, chloride, acid, sour water, Flue gas, caustic, ammonia, polythionic acids, olefins, aromatics-how they affect carbon steel at ambient condition.
• Plant and machinery- pipes, storage vessels, reactors, pumps, compressors valves- heat exchangers-typical problems and failure patterns

Day 3 Importance and principle of Cryogenics

• What are cryogenics? - History of development-of liquefaction of air- the success and problems in containment transport and materials
• Introduction to Natural gas separation and purification- Cryogenic separation in production and associated impurities- solvents, gases, particulates - gas liquefaction and purification

Day 4 Cryogenics and metallurgy

• How carbon steel is affected by low temperature
• Introduction to Stainless steel – types and classification- how it is affected under wet gas condition-case study of failed components- stainless steel failure in production and transport of oil and gas mixture- failure under complex condition of H2S, CO2, Cl, O2, moisture in varying quantities.
• Stainless steel in cryogenic application
• Stainless steel as cast components, lining and cladding material.
• What are Polymers? Their application for cryogenics

• Storing and transport issues
• Weldment failures
• Coating issues
• Cost versus reliability
• Health and safety issues

Day 5 Material testing and failure analysis

• Laboratory analysis by atomic spectra
• Particulate analysis by SEM, EDX
• Acoustics for cracks and leaks
• FEA for new and old equipment

NOTE:

Pre & Post Tests will be conducted

Case Studies, Group Exercises, Group Discussions, Last Day Review &Assessments will

be carried out.

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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 motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions