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METALLURGY FOR NON - METALLURGISTS

Location
Dubai, UAE
Date
From Date: 11-Aug-2025   
To Date: 15-Aug-2025
Duration
5 days
Language
ENGLISH
Discipline
Welding, Metallurgy, Corrosion & Inspection
Introduction

Although Carbon steel has been the first and most widely used material in oil fields and other industries, 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 the loss of assets and lives. Plants 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 are a matter of equal importance Do metals fail due to normal out only or do they suffer from stress and fatigue and have aging problems as humans? What are the tools available to test the reliability of old and new materials? What are codes and standards for correct and economical material selection?

Objective

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

Audience

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.

Content

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
      • Au forming
      • 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 an 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 an offshore environment

Selection of materials for wellheads

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

 

Day 4

Selection of material using codes and standards

  • Brief overview 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

Nonferrous metals and non-metals in the gas and oil industry

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

 

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

 

  • Design considerations

 

  • Welding
  • Joining

 

  • Safety, health, and environment.

NOTE:

Pre & Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day Reviews & Assessments will be carried out.

…………………………………………

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

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
Fees
• $5,500 per participant for Public Training includes Materials/Handouts, tea/coffee breaks, refreshments & Lunch

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