A ruptured elbow in the piping associated with a hydrocracking unit air cooler released hydrocarbons and hydrogen to the atmosphere, creating a flammable vapor cloud and liquid pool. The vapor cloud migrated to an ignition source, exploded and ignited the liquid pool. The explosion and subsequent fire caused many more piping ruptures, supplying additional hydrocarbons that fed the fire.

A multidisciplinary team from Exponent analyzed the process conditions within the air cooler piping, performed a metallurgical analysis on the fractured piping, and characterized the release of flammable hydrocarbons from the original and subsequent piping ruptures. To accomplish these tasks, we reviewed process data from before and during the incident, laboratory data from samples drawn prior to the incident, process design material and heat balances, mechanical drawings for all of the vessels in the unit, photographs of the damage, and other damage assessment information.

Five Days Public Training

Hyatt-Sanur Bali 24-28 September 2012

FOREWORD:

The Piping Systems & Pipeline Code establishes rules of the  design, inspection, maintenance and repair of piping systems and pipelines throughout the world. The objective of the  rules is to provide a margin for deterioration in service. This course will center on the on the practical aspects of  piping and pipeline design, integrity, maintenance and repair.

OBJECTIVES:

1. The Participant will gain an in-depth knowledge of pipe  and fitting material specifications, manufacturing, fabrication process and their influence on mechanical properties of strength and toughness, to help in material selection and failure analysis

2. The participant will understand the technical background to  the design formulas, and their application to the design of piping systems and pipelines. The course addresses rules of good practice in layout of piping systems for reliable operation

3. The participant will gain a practical understanding of piping and pipeline mode of failure, corrosion mechanisms, how to recognize them, classify them and resolve them

4. The participant will learn risk assessment for piping & pipeline i.e. probability of failure and their consequences if failures occur

5. The participant will be introduced to the latest techniques and research in piping and pipeline integrity to analyze a degraded condition due to either corrosion or mechanical damage.

COURSE OUTLINE:

1. Introduction

- History of Pipeline Technology – ASME Codes and Standards – API Standards – NACA, MSS-SP, PFI Standards – Fundamentals of Maintenance and Integrity

2. Materials Selection

- API 5L and ASTM Specifications – Practical Aspects of Metallurgical Properties – Chemistry and Material Test Reports – Linepipe manufacturing – Fabrication and Fittings specification – Mechanical Properties: Strength and Toughness – Material selection technique

3. Welding

- Overview of Pipe and Pipeline Welding Practice – API 1104 and ASME IX Requirement – Welding In-service: Challenge and Solutions

4. Strength Integrity for Sustained Loads

- Operating and Design Pressure – How to Establish the System Design Pressure – Introduction to Pressure Relief Valves – Pipe and Pipeline Sizing Formula with Applications – Rules of Good Practice in layout – Pump and Compressor Piping – How to Support a piping System – Review of Support Types and their Application – Lesson learned from Poor Support Practices – Temperature Effects – Flexibility Layout Analysis – Temperature Transients and Fatigue Damage – Vibration In Service – Mechanical and Hydraulic Induced Vibration in Piping – How to Measure Analyze Resolve Vibration

5. Strength Integrity for Occasional Loads

- Pressure Transients – Recognizing and Solving Liquid Hammer – Pump Station Transients – Study of Pipeline Failures Due to Transient – Two-Phase Liquid -Vapor Transients – Two-Phase Liquid-Gas Transients – Gas Discharge Transients – Buried Pipe – Soil Loads – Surface Loads – Expansion of Buried Pipe – Soil settlement – n-service Movement of Pipeline – Pipeline Failures – Study Case Histories – Understanding Why Failures Occur and How to Avoid Them

6. Corrosion Assessment and Protection

- Introduction to Practical Corrosion – Classification of Corrosion Mechanisms – General Wall Thinning – Local Corrosion: Galvanic Effects – Crevice Corrosion – Pitting Corrosion – Environmental Effects – Hydrogen and H2S Effects – Microbiological Corrosion – Corrosion Protection – Cathodic Protection Overvie

7. Corrosion Assessment and Protection

- Introduction to Practical Corrosion – Classification of Corrosion Mechanisms – General Wall Thinning – Local Corrosion: Galvanic Effects – Crevice Corrosion – Pitting Corrosion – Environmental Effects – Hydrogen and H2S Effects – Microbiological Corrosion – Corrosion Protection – Cathodic Protection

8. Risk Assessment Overview

- Introduction to risk assessment – Risk Criteria – Probability of failure – Third party damage – Corrosion aspects – Design aspects – Incorrect operation – Consequence of failure – Product hazard – Spill assessment – Dispersion calculation – Receptors – Risk Representation

9. Maintenance & repair

- Flange and Mechanical Joints – Overview of Different Types of Flanges and Application – Causes of Flange Leaks and How to Resolve – Case Study of Flange Failure – Assembly of Flange Joints and Leak Tightness – Pressure and Leak Testing – The Difference Between Leak Testing and Pressure Testing – Review of Difference Testing Techniques – The Purpose of Hydro test – How to Conduct a Hydro test – Pipeline and Piping Systems Testing – Pneumatic Testing – Repair Techniques – The New ASME Repir Standards – The Fundamentals of Repair package – Pipe and Component Replacement – Grinding and welding – Welded Sleeve: Type A and B

RECOMMENDED PARTICIPANTS:

Plant engineers in mechanical reliability programs, structure engineer, plant inspectors, central engineering staff, and consultants for refining and petrochemicals. Piping & Pipeline Integrity Management System with ASME CODES STANDARDS can also be beneficial for the pulp, paper, fossil fuel utility, and other industries that use and maintain the piping and pipeline integrity system.

DATES & VENUE:

* DATES : 24–28 September 2012

* Time : 8.00 am – 4.00 pm

* VENUE : Hyatt-Sanur, Bali

COURSE ORGANIZER:

Handal Consulting, Training & Services

* Address : Jl. Danau Semayang Blok BIII No. 104,Pejompongan,

* Jakarta 10210

* Website : http://www.handaltraining.com

* Phone : 021 – 5708775

* Fax : 021 – 5702113

* 24 hours Info : 021-70897550

* SMS: 081511831936

COURSE FEES:

Course Fee: Rp. 8.000.000,- / delegate including: training modules, merchandise, seminar kit, training certificate, 2 x coffee break & lunch and excluding accommodation & tax

INSTRUCTORS:

The Instructors for this short course will be given by expert in certain field that is:

* Prof. Dr. Ir. IGN WIRATMAJA & Team Profesional experience: Prof. Dr. Ir. IGN Wiratmaja Puja earned his Bachelor degree from Institut Teknologi Bandung; Master & Doctor of Philosopy in Engineering Mechanics, University of Kentucky, USA. He was also did his Post Doctoral in Tokyo Institute of Technology, Japan, and the University of Sidney, Australia. More than 20 years in mechanical engineering especially in failure and stress analysis, mining machinery and design as well as mechanical drawing and he has been a consulting engineering expert in machinery, pipeline, piping and equipment maintenance such as; PT. Tambang Batubara Tanjung Enim, KONDUR Petroleum and PT. Kereta Api Indonesia, Conoco Phillips, CNOOC, BP-Indonesia, etc. He also has served as an in-company training instructor for several major oil and gas companies such as PT. Badak LNG, PT. Freeport Indonesia, VICO and PT. Timah Tbk, Handal Consulting & Training. Prof. Dr. Ir. IGN Wiratmaja Puja has authored numerous publications and Presentations related to mechanical engineering and mining machinery.

Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid.

Industrial process piping (and accompanying in-line components) can be manufactured from wood, glass, steel, aluminum, plastic, copper, and concrete. The in-line components, known as fittings, valves, and other devices, typically sense and control the pressure, flow rate and temperature of the transmitted fluid, and usually are included in the field of piping design. Piping systems are documented in Piping and Instrumentation Diagrams (PID). If necessary, pipes can be cleaned by the tube cleaning process.

Plumbing is a piping system that most people are familiar with, as it constitutes the form of fluid transportation that is used to provide potable water and fuels to their homes and business. Plumbing pipes also remove waste in the form of sewage, and allow venting of sewage gases to the atmosphere. Fire sprinkler systems also use piping, and may transport potable or nonpotable water, or other fire-suppression fluids.

Piping also has many other industrial applications, which are crucial for moving raw and semi-processed fluids for refining into more useful products. Some of the more exotic materials of construction are titanium, chrome-moly and various other steel alloys.

CONTENTS

• Introduction
  Purpose .
  Applicability
  References
  Distribution
  Scope
  Metrics
  Brand Names
  Accompanying Guidance
  Specification
  Manual Organization
• Design Strategy
  Design Analyses
  Specifications
  Drawings
  Basis of Design
  Loading Conditions
  Piping Layout
• General Piping Design
  Materials of Construction
  Design Pressure
  Sizing
  Stress Analysis
  Flange, Gaskets and Bolting
  Materials
  Pipe Identification
  Piping Supports
  Testing and Flushing
• Metallic Piping Systems
  General
  Corrosion
  Design Pressure
  Piping Supports for Metallic
  Piping Systems
  Joining
  Thermal Expansion
  Ductile Iron
  Carbon Steel
  Nickel and Nickel Alloys
  Aluminum
  Copper
• Plastic Piping Systems
  General
  Polyvinyl Chloride (PVC)
  Polytetrafluoroethylene (PTFE)
  Acrylonitrile-Butadiene-Styrene
  ABS
  Chlorinated Polyvinyl Chloride
  CPVC
  Polyethylene (PE)
  Polypropylene (PP)
  Polyvinylidene Fluoride (PVDF)
• Rubber and Elastomer Piping Systems
  General
  Design Factors
  Sizing
  Piping Support and Burial
  Fluoroelastomer
  Isobutylene Isoprene
  Acrylonitrile Butadiene
  Polychloroprene
  Natural Rubber
• Thermoset Piping Systems
  General
  Reinforced Epoxies
  Reinforced Polyesters
  Reinforced Vinyl Esters
  Reinforced Furans
• Double Containment Piping Systems
  General
  Piping System Sizing
  Double Containment Piping
  System Testing
  Leak Detection Systems
• Lined Piping Systems
  General
  Plastic Lined Piping Systems
  Other Lined Piping Systems
• Valves
  General
  Valve Types
  Valve Sizing and Selection
  Valve Schedule
• Ancillary Equipment
  Flexible Couplings
  Air and Vacuum Relief
  Drains
  Sample Ports
  Pressure Relief Devices
  Backflow Prevention
  Static Mixers
  Expansion Joints
  Piping Insulation
  Heat Tracing
  Corrosion Protection
  Cathodic Protection
  Isolation Joints
  Protective Coatings
• Corrosion Protection
  Corrosion Protection
  Cathodic Protection
  Isolation Joints
  Protective Coatings

LEARNING OUTCOMES / OBJECTIVES

At the end of the program, participants will be able to: Develop a working knowledge of piping systems ; Differentiate between the different classes of piping; Understand better the design, construction, operations and maintenance requirements of piping systems; Implement strategies and methodologies to create an effective piping maintenance program; Enhance their knowledge and skills to identify and address piping operational problems at all levels; Implement mechanisms to measure piping performance at all levels; Analyse and understand the impact of piping knowledge on the maintenance strategy; Develop and implement an effective piping maintenance budget; Use life cycle costing techniques to deliver best practice piping maintenance; Implement maintenance plans that are cost effective and aligned to the organisations strategic goals; Improve performance by developing detailed specifications with service partners; Establish an effective maintenance team.

WHO SHOULD ATTEND

Facilities engineers, maintenance engineers, design engineers, production and manufacturing engineers, architects, property and asset managers, technicians and any one involved in piping systems and would like to widen their knowledge.

DATES & VENUE

****************

• DATES : 17–21 October 2011
• TIME : 8.00 am – 4.00 pm
• · VENUE : MELIA PUROSANI-YOGYAKARTA
• Jl. Suryotomo no 31, 55122, Java INDONESIA

Course Organizer

Handal Consulting & Training

Jl. Danau Semayang Blok B3 No. 104

Pejompongan, Jakarta 10210

Website:http://www. handalconsulting.com

http://www.handaltraining.com

Phone: +62 21 – 5708775

Fax : + 62 21 – 5702113

24 Hours INFO: +62 21-70897550

Fees

Course Fee: Rp. 8.000.000,- including: training modules, merchandise, seminar kit, training certificate, 2 x coffee break & lunch, excluding accommodation and tax

Instructor
Prof. DR. Ir. IGN. Wiratmaja Puja

Prof. DR. Ir. IGN. Wiratmaja Puja has 16 years continuous mechnanical engineering experience in failure and stress analysis, mining machinery and design as well as mechanical drawing and has been a consulting engineering expert in machinery and equipment maintenance for PT. Tambang Batubara Tanjung Enim, KONDUR Petroleum and PT. Kereta Api Indonesia. He also has served as an in-company training instructor for several major oil and gas companies such as PT. Badak LNG, PT. Freeport Indonesia, VICO and PT. Timah Tbk.

Mr. Wiratmaja has authored numerous publications and presentations related to mechanical engineering and mining machinery. He holds a M.Sc. and Ph.D. degree in Mechanical Engineering from the University of Kentucky, USA.

Three Days Workshop July 2011
Jakarta

OBJECTIVES:

The participants will learn Fitness for Service (FFS)  assesment techniques for piping & pressure vessels that experience general, local and pitting corrosion; crack like  flaws. The participants will also learn the remaining life assesment and remediation for the specified defects.

WHO SHOULD ATTEND?
The course is intended for mechanical integrity engineers,  piping/pipeline engineers, maintenance engineers &  supervisors, service engineers & supervisors, inspectors,  work over engineers & supervisors, plant engineers.

COURSE OUTLINE:
1.Introduction to Fitness for Services
a.Defect &
b.Applicability & Limitation
c.Data Requirements
d.Assesment Technique & acceptance Criteria
2.Assesment of General Metal Loss
a.Catagory of Wall Thinning
b.Data Requirements
c.Assesment level 1&2
3.Assesment of Local Metal Loss
a.Local Corrosion
b.Data Requirements
c.Assesment level 1&2
4.Assesment of Pitting Corrosion
a.Pitting identification
b.Data Requirements
c.Assesment level 1&2
5.Assesment of Crack Like Flaws
d.Crack identification
e.Data Requirements
f.Assesment level 1&2
6.Remaining Life Assesment & Repair
a.Remaining Life Asseement
b.Repair Work Package
7.FFS Calculator
a.Case Studies

DATES & VENUE:

DATES : 2011
TIME : 8.00 am – 4.00 pm
VENUE : BANDUNG

Course Organizer

Handal Consulting, Training & Services
Jl. Danau Semayang Blok B3 No. 104
Pejompongan, Jakarta 10210
Website: http://www.handalconsulting.com

Phone: +62 21 – 5708775
Fax : + 62 21 – 5702113
24 Hours Info: +62 21-70897550,
SMS: 0815 11831936

Course Fees
Course fee is Rp. 5.000.000,- /delegate and including; lunch, training kit, 2 x Coffee break/day, Course certificate,
excluding accommodation and Tax.

ABOUT INSTRUCTORS:

Prof. Dr. Ir. I. Wiratmaja Puja earned his Bachelor degree  from Institut Teknologi Bandung; Master & Doctor of Philosopy  in Engineering Mechanics, University of Kentucky, USA.  He was also did his Post Doctoral in Tokyo Institute of  Technology, Japan, and the University of Sidney, Australia.  His work experiences for more than 20 years are in mechanical integrity, piping/pipeline, surface facilities, risk assesment  and system integrity for oil and gas facilities, i.e; PERTAMINA, CONOCPHILLIPS, BP-INDONESIA, CNOOC, KONDUR, etc

APPLICABLE CODES & STANDARDS:
1.API RP 579
2.ASME B 31
3.ASME BPV

Notes:
The course will be in Bahasa Indonesia
The participants are expected to bring laptop for the FFS
calculator impelementation & case studies

13-17 June 2011, Aston-Hotel, Bandung

FOREWORD

This course has been specificaly designed to meet the practical need of design requirements and objectives that comply with the requirements of industry codes and standards. The Fundamentals of Piping Design is an introduction to the design of piping systems, various processes and the layout of pipe work connecting the major items of equipment for the new hire, the engineering student and the engineer who need a valuable reference for their continous professional development.

CAESAR II is a comprehensive program for pipe stress analysis. CAESAR II has become a popular program for pipe stress analysis, preferred by many major corporations and engineering firms worldwide. This software also includes a full range of the latest international piping codes. It provides static and dynamic analysis of pipe and piping systems b. The program automatically models structural steel and buried pipe and provides spectrum and time history analysis and automatic spring sizing. CAESAR II includes component databases and an extensive material database with allowable stress data.

This course is really a demonstration of finite element method that known as a established techniques for analysing the behaviour of piping structures subjected to variety of loads. It also is dedicated to personnel from a wide range of abilities and backgrounds and will cover the fundamental principles and concepts used in pipe stress analysis. In order to meet the course objcetives and practical exercises during the course, the participant should bring their own personal computer (laptop) and we provide a copy of the CAESAR II pipe stress analysis program for use during the course.

THE PARTICIPANTS

The course is aimed at who intend to use commercially available finite element packages (CAESAR II) to analyse piping system in petrochemical, oil and gas and other engineering industries, i.e; Piping Engineers, Piping Designer, Mechanical Engineers, Maintenance Engineers and supervisors, Service Engineers and supervisors, Work over engineers and supervisors, Plant Engineers, Petroleum Engineers

COURSE CONTENTS

A. Fundamental Theory:
- Fundamental Stress MethodsIntroduction. Brief history. Piping system. Pipeline system. Codes, standard, and regulation. Codes & standards agencies.
- Piping Systems: Codes, Standards and Regulations
Piping Design Loads Introduction. Sustain Loads: weight: pressure. Occasional Loads: wind; relief valve discharge: seismic. Expansion Loads. Load Combinations. Vibration Aspects.
- Pipe Stress RequirementReview of Failure Theory. Stress Categories. Fatigue Aspect. Service Levels and Loads. B31 Basic Reference Data & Formula.
- ANSI Piping Codes and ASME Codes
- Pipe Support Systems
- Pipe Stress AnalysisStatic Review: force and moments, equilibrium state, free body diagram. Stress review: stress state, stress due to various loading (axial, bending, torsion, and shearing). Stress in pipe (hoop, longitudinal, and radial stresses). Stress analysis: principal stresses, Mohr circle, stress intensification factor (SIF).

B. CAESAR II SOFTWARE APPLICATION:
- Main Menu Piping Spreadsheet. Auxiliary Field. Support Spreadsheet. Preprocessing. Analysis Procedure. Error Checking. Output Processing.
- Modelling Approach Anchors. Bends. Cuts. Restraints. Flexible Joints. Frames. Hangers. Nozzles. Pipes. Reducers. Rotating Equipment. Tees. Valves. Vessels.
Load case.
- Static Linear Analysis. Nonlinear Analysis. Support Gap and Friction Properties. Spring Directions: one-point and two-point supports. Soil Yield Effects. Y-Stop Lift-Off. Weightless Vs. As Built Gap Treatment. Solution Sequence. Displacement Tolerance. Force Tolerance and Friction Tolerance. Failure to Converge. Hanger Analysis.
- Dynamics AnalysisModal Analysis : general principle of static correction methods, missing mass correction, zero period acceleration (ZPA) correction, mass discretization. Response Spectrum Analysis: square root of the sum of the squares (SRSS), grouping
method, ten percent method, double sum method. Harmonic Analysis. Force Spectrum. Sismic Anchor Movement Analysis.
- Structural and Buried PipelinePipe-Soil Interaction. Properties for a Horizontal Pipe Orientation. Properties for a Vertical Pipe Orientation. Determination of Zone Locations. Define the Transition. Soil Forces and Deformations. Report. Conclusions. Output ProcessingCoordinate Systems. Total vs. Incremental Loading. Pipe Displacements. Pipe Forces and Moments: global option, anchor forces, support forces. Support Deformations. Straight Pipe Forces and Moments. Curved Pipe Forces and Moments. Frame Member Forces. Stress Intensification Factors. Hoop Stress. Longitudinal Stress. Torsional Shear Stress. Principal Stress. Maximum Shear Stress. Location of Maximum Shear Stress. Octahedral Shear Stress.

COURSE FEES
******************

Course fee is 8.000.000 IDR,-/delegate and including: lunch, training kit, 2 x Coffee break/day, 5 days tutorials, excluding accommodation and Tax.

DATES & VENUE
*****************

DATES :  13-17 June 2011
TIME : 8.00 am – 5.00 pm
VENUE : ASTON-HOTEL
Jl. Cihampelas 125 – 129. Bandung 40131 – Indonesia
E : Info@AstonTropicana.com t : +62-22-203 0101

COURSE ORGANIZER:
Handal Consulting, Training & Services

* Address : Jl. Danau Semayang Blok BIII No. 104,Pejompongan,
* Jakarta 10210
* Website : http://www.handalconsulting.com or
* http://www.handaltraining.com
* Phone; 021 – 5708775
* Fax ; 021 – 5702113
* 24 hours Info ; 021-70897550, 081511831936

INSTRUCTOR

DR. Ir. I Wayan Suweca has been a senior consulting engineer specialist for PT. TIMAH Tbk., PT. TAMBANG BATUBARA Bukit Asam, KONDUR Petroleum S.A., and PT. KAI whereas he has been involved in failure analysis of machineries and equipments design. Mr. Wayan also is a distinguished professor of mechanical engineering at ITB since 1987 and has conducted numerous short courses and seminars for various major oil companies such as PT. CALTEX Pacific Indonesia, PT. FREEPORT Indonesia as well as VICO. His field of expertise includes mechanical design and drawing, stress analysis and computer aided MSC/Nastran finite element program, mining hydraulics, and vibrations control as well as maintenance management. Mr. Wayan received his Ph.D. in Mechanical Engineering from Ecole Centrale de Lyon, French in 1990.