COURSE OVERVIEW:

Materials of construction for process equipment and piping systems are the critical determinants of safety, performance, and longevity in the process industries. This course provides a technical deep-dive into the selection process for the metals and non-metals used to contain and transport hazardous fluids, gases, and slurries. Participants will learn how to navigate the complex landscape of international codes, such as ASME Section II and B31.3, to ensure that chosen materials are fit for purpose across a wide range of operating temperatures and pressures.

The scope of this training encompasses the metallurgy of carbon steels, stainless steels, and high-nickel alloys, alongside the emerging use of non-metallic materials like GRP and PTFE-lined systems. Coverage includes the specific environmental challenges found in process plants, such as sulfidation, hydrogen attack, and cryogenic conditions. Emphasis is placed on the mechanical integrity of the system, ensuring that material choices account for weldability, thermal expansion, and the potential for localized degradation over decades of service.

Furthermore, the course addresses the lifecycle management of materials, from the design phase through to inspection and maintenance. Trainees will explore how to interpret corrosion data to establish corrosion allowances and how to select materials that facilitate ease of inspection. By mastering the principles of material construction, process engineers and designers can minimize the risk of loss of containment, optimize capital expenditure, and ensure the long-term reliability of complex industrial facilities.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Interpret ASME and ASTM standards for process equipment materials.
• Select appropriate carbon steels for general and low-temperature service.
• Differentiate between austenitic, ferritic, and duplex stainless steels.
• Evaluate the suitability of nickel-based alloys for highly corrosive environments.
• Apply corrosion allowance calculations to the design of piping and vessels.
• Identify the risks of High-Temperature Hydrogen Attack (HTHA).
• Select materials for cryogenic applications based on notch toughness.
• Assess the performance of non-metallic liners and composite piping.
• Determine the impact of alloying elements on weldability and fabrication.
• Analyze the cost-performance trade-offs of different material options.
• Conduct a basic material compatibility review for new chemical processes.
• Utilize Material Test Reports (MTR) to verify chemical and physical properties.
• Recommend material upgrades for equipment in chronic failure cycles.

TARGET AUDIENCE:

This course is intended for Process Engineers, Piping Designers, Mechanical Engineers, and Asset Integrity Professionals responsible for the specification and selection of materials for process plants.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.