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Engineering Failures

and their lessons

Eric Vreugde Consulting Metallurgist Metserve International

28 February - 1 March

2013 Indaba Hotel

When a part breaks unexpectedly, it usually sets off a flurry of activities....

Critical component failures often make the headlines, whether occurring at sea, underground, in mid-air or in production plants. Faulty pipes, valves, shafts, gears, couplings and other engineered components give rise to safety, environmental, productivity and financial issues, some catastrophic. These failures might result from design, manufacturing and assembly errors, inadequate quality assurance or unforeseen operating conditions, but sometimes they relate just to substandard materials and improper processing treatments. Failure Analysis or Failure Diagnosis is the first step in identifying the correct solution to a problem to prevent it from happening again! In a recent survey, it may shock you to learn that it was estimated that a staggering 80% of the maintenance budget gets eaten up dealing with these ongoing types of engineering failures and no matter what company you work for or industry you are in that is a huge amount of money! Unexpected failures can be prevented if more people know and understand the degradation and failure mechanisms of power plant and refinery equipment, why they happen and how to prevent them from resulting in catastrophic failure

Training Methodology

The training methodology is inter-active with numerous exercises and is suitable for all employees involved in maintenance and operations management. Participants are encouraged to ask questions and comment on topics during the course. Visual aids are used extensively using actual case histories. Emphasis on basic principles and fundamentals. Practical application rather than theory stressed throughout.

Course Overview
Events Information
Date: Duration: Time: Venue: Location: Country: Organizer: 28 Feb. - 1 March 2013 2 day 08h30 to 16h30 daily Indaba Hotel Fourways South Africa Business success

Learning Objectives

Upon completion of this course, participants will: Understand damage mechanisms (creep,fatigue,corrosion etc) applicable in all industries and be able to identify their features & functions and making recommendations that will minimize the risk of repeat failures.

Who Should Attend?

Course Materials

Comprehensive course documentation is made available after the course which serves as a valuable reference material for future use. The documentation also make any need for note taking minimal, which increases comprehension, understanding, and retention of the material, as delegates are free to concentrate more fully on the presentations and visual aids.

Engineering and Technical Professionals from the industry Plant Engineers and Maintenance Professionals Section Engineers and Inspectors. Reliability Professionals


The course has been awarded 2 CPD points for attendees, who need to gain the points for 2013.

For registration and more information:

please contact: Magnum Govender Tel: 011 475 4775 Cell: 078 614 2847 Fax: 086 572 2434 E-mail: magnum@businesssuccess.co.za

Course Fees:

Fee includes: Course Materials Certificate Refreshments and Lunch Accommodation is not included in the Program fee.

About Your Expert Course Leader

Eric Vreugde, founder of Metserve International a metallurgical consultancy who conduct failure analysis and provide material related solutions to national and international clients since 1980. (Over the last 30 years he has undertaken thousands of failure investigations, for the power ,refining and petrochemical industry) Areas of technical expertise include failure analysis, equipment condition assessment and remaining life evaluation for the high temperature components. Mr. Vreugde a metallurgist by profession has published several international papers related to failure investigations and has been a speaker at several national and international professional conferences.

Program Day One
Guide line for Failure Analysis Exercise - Real life case studies. Mid-morning refreshments and networking What can you learn from fatigue fractures? Exercise Fatigue Fracture Interpretation. Explanation Fatigue Fracture Interpretation Exercise Questions Fatigue Failures to delegates. Lunch Discussion Exercise Group - Real life case studies Questions Fatigue Failures Answers Sources of Failures. Mid-afternoon refreshments and networking Corrosion Failures Part one Discussion and closing remarks. End of Day

Sources of failures
This module reviews a selection of industrial plant related failures and explains how errors or defects can lead to failures. Errors in assembly. Service abnormalities. Inadequate maintenance. Unintended or inadvertent factors Fire Damage. Improper maintenance. Material Related. Fabrication defects. Improper processing. Deficiencies in design. Incorrect Repair Welding

Fatigue fractures Interpretations

This module reviews a selection of fatigue fracture faces and provides information applicable to the interpretation of various fracture faces. What is metal fatigue. Fatigue zone. Progression mark. Fatigue striations. Overload zone. Ratchet mark. Stress concentrations. Factors affecting fatigue life. Recognizing the type of loading from the fracture surface. Test with the aid of actual cases. Prevention of fatigue failures.

Guidelines for Failure Analysis

This module aims to provide the participants with an understanding to identify the steps necessary in any failure investigation. Errors of knowledge Errors of performance Errors of intent Objective of Forensic Analysis The value of Forensic Analysis When a Forensic Analysis is Important Preliminaries Site Visit Photographic Documentation Selection and Removal of Samples Preservation of Samples Onsite - Metallography Forensic Analysis Methods Fractography The Scanning Electron Microscope Metallographic Examination Mechanical Testing Technological Tools Use of animation Failure analysis rules The DO & DONTs

Corrosion Failures Part One

The module aims to provide delegates with an understanding of why and how corrosion occurs, the metallurgical and environmental factors influencing corrosion, and practical methods of corrosion control and failure prevention. Uniform corrosion.Galvanic corrosion. Dealloying and Graphitization. Crevice corrosion. Pitting corrosion. Intergranular stress corrosion cracking, weld decay and knife-line attack. Microbiologically-influenced corrosion (MIC) Each Corrosion mechanisms are presented with actual case histories from industry.

Program Day Two
Opening and Welcome Concept of Risk Base Inspection Exercise - Real life case studies Mid-morning refreshments and networking Corrosion Failures Part two. Exercise Group -Real life case studies. Lunch Discussion Exercise Group - Real life case studies. Boiler Tube Failures Identification of the damage and failure mechanism Pt 1. Boiler Tube Failures Interactive Exercise Visual & Micro-structures Mid-afternoon refreshments and networking Readily Preventable Failures 20 Questions Answers - Discussion Questions Issue of certificates and closing remarks.

Stress Corrosion Cracking. Hydrogen Embrittlement. Metal Dusting Liquid Metal Embrittlement. Corrosion Fatigue. Erosion corrosion, impingement attack and cavitation damage. Each Corrosion mechanisms are presented with actual case histories from industry.

Boiler Tube Failures Identification of the damage and failure mechanism Part one.
Boiler tube failures are the leading cause of steam plant non-reliability. A tube failure may cause a forced outage, usually at the most inopportune time. Long-term Overheating Dissimilar Metal Weld (DMW) Failure Water and Steam formed deposits Waterside Corrosion Fatigue Oxygen Pitting Caustic Related cracking Fire Site Ash Corrosion Short-term Overheating Why metallurgical examination

Concept of Risk Based Inspection

Risk Based Inspection (RBI) methodology enables the assessment of the likelihood and potential consequences of pressure equipment failures. The module is based on API 580. Reasons for implementing Risk Based Inspection (RBI) Benefits of using Risk Based Inspection (RBI) Risk Assessment - Probability of failure, consequences of failure Practical likelihood and consequence analysis Review of data and information requirements for the RBI assessment identification of the operative damage mechanisms

Readily Preventable Failures: Cost and Consequences

Of the many failures examined by the author each year it is evident that many of them are relative simple metallurgically and could readily have been prevented. Prevention may have been effected by inexpensive design changes or material selection but the consequences of failure have had significant cost in production and plant losses. This module reviews a series of such cases with an underlying theme of fatigue and show how prior metallurgical, design or operational consideration could have prevented failures and the associated cost and consequences.

Corrosion Failures Part Two.

The module aims to provide delegates with an understanding of why and how corrosion occurs, the metallurgical and environmental factors influencing corrosion, and practical methods of corrosion control and failure prevention Environment-sensitive cracking.