Material Selection and Failure Analysis

Curriculum / Syllabus

Day 1 – Fundamentals of Material Selection & Failure Analysis

Module 1: Introduction to Material Selection

• Purpose of material selection in equipment and piping
• Role of process and mechanical designers
• Life-cycle cost concept
• Maintainability, safety, and replacement considerations

Module 2: General Aspects of Material Selection

• Environmental compatibility
• Aqueous corrosion
• High-temperature attack (oxidation, sulfidation, hydrogen damage)
• Metallurgical degradation (phase precipitation, spheroidising, hydrogen embrittlement, temper embrittlement)
• Mechanical and physical property requirements

Module 3: Introduction to Failure Analysis

• Objectives of failure analysis
• Consequences of failure (People, Environment, Asset, Reputation)
• Principles of failure analysis
• Qualities of an analyst
• Failure analysis tasks (Prioritize – Analyze – Recommend)
• First principle: Observe – Do Not Touch
• Importance of visual examination and operating conditions

Day 2 – Mechanical Properties, Corrosion & Failure Modes

Module 4: Mechanical Properties of Engineering Materials

• Tensile strength
• Toughness
• Hardness
• Fatigue
• Creep
• Effects of high temperature
• Effects of low temperature (Charpy impact testing)
• Influence of alloying elements

Module 5: Corrosion Resistance Considerations

• Temperature, pressure and pH effects
• Impurities and stress corrosion
• Aeration and erosion-corrosion
• Heat transfer influence

Module 6: Types and Modes of Failure

• Types of failures: ductile, brittle, fatigue, deformation, embrittlement
• Permanent distortion
• Fracture (ductile, brittle, fatigue, creep, SCC, hydrogen embrittlement)
• Surface damage (wear, fretting, cavitation, thermal fatigue, corrosion)

Module 7: Causes of Failure

• Design errors
• Improper materials and heat treatment
• Manufacturing defects
• Assembly and maintenance errors
• Environmental effects
• Unforeseen operating conditions

Day 3 – Material Grades, Design Codes & Failure Investigation Methods

Module 8: Material Types and Grades

• Carbon steels
• Stainless steels (Austenitic, Ferritic, Duplex, Martensitic, 17-4 PH)
• Low alloy steels and HSLA steels
• Nickel alloys (Monel, Inconel, Hastelloy)
• Aluminium alloys
• Plastics (Thermoplastic & Thermosetting)
• Refractory materials

Module 9: Refinery Design References

• Iron–Carbon phase diagram
• McConomy curves
• Couper–Gourman curve
• NACE MR0175 / MR0103
• Nelson Curve (API 941)
• ASME UCS-66
• API 945

Module 10: Failure Analysis Methodology

• Practical inspection issues
• Steps and stages of failure analysis
• Sample preparation
• Data collection techniques
• Visual examination rules
• Chemical analysis
• Metallography
• Fractography & SEM
• Mechanical testing
• Surface evaluation
• Finite Element Analysis (FEA) and simulation

Day 4 – Refinery Applications, Degradation Mechanisms & Prevention

Module 11: Refinery Equipment Material Applications

• Crude Distillation Unit (CDU)
• Vacuum Distillation Unit (VDU)
• Fluid Catalytic Cracking Unit (FCCU)
• Hydrocracker
• General refinery process flow

Module 12: Degradation Mechanisms in Refineries

• Sulfidation
• High-Temperature Hydrogen Attack (HTHA)
• Creep
• Polythionic Acid Stress Corrosion Cracking (PTA SCC)
• Amine Stress Corrosion Cracking
• Wet H₂S Damage
• Ammonium Bisulfide Corrosion
• HCl Corrosion
• Naphthenic Acid Corrosion
• Sour Water Corrosion
• Sulfuric Acid Corrosion

Module 13: Corrosion Control & Failure Prevention

• Material selection
• Design improvement
• Heat treatment
• Metallic cladding and lining
• Corrosion inhibitors
• Cathodic protection
• Protective coatings

Module 14: Failure Prevention & Reporting

• Prevention through design, materials, processing and service control
• Failure analysis report structure
• Case histories and real-world failure examples