Course Content – SynGas Plants – Preventing Fixed Equipment Failures

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?

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

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

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.