Materials Selection and Failure Analysis

Mechanical equipment and systems often handle hazardous or even deadly substances, many of which are also corrosive. These systems typically operate under high temperatures and pressures and face service conditions that can lead to degradation and damage. If such damage is not detected and evaluated promptly, it may result in catastrophic failures, potentially causing significant loss of life and assets.

When designing this equipment, it is crucial to consider potential degradation mechanisms such as fracture, corrosion, erosion, fatigue, and creep, among others. These risks are usually addressed in the design by selecting suitable construction materials, allowing for additional thickness to account for corrosion, implementing control measures, and integrating safeguards to prevent operating conditions that exceed the design limits, ensuring the integrity of the equipment. In some cases, replacing the equipment or system may be necessary.

As a result, regular inspections of mechanical equipment and systems are essential to identify any damage, assess its impact on equipment integrity, and perform Fitness-for-Service evaluations.

This Materials Selection and Failure Analysis training course aims to equip participants with a thorough understanding of the materials selection process and the degradation mechanisms mechanical equipment may face during its service life. Participants will learn how to identify, predict, and assess the impact of these mechanisms, and what measures can be taken to prevent and control the resulting damage.

Additionally, the course will cover necessary actions to maintain or restore systems to a serviceable condition, including servicing, repair, modification, overhaul, inspection, and condition verification. These actions enhance system availability and help ensure that the equipment remains in operational condition.

This training course will feature:

• Study of mechanical faults related to mechanical equipment
• Failure modes including fracture, fatigue, high temperature creep and corrosion damage
• Materials types and selection
• Condition monitoring and trending
• Knowledge of non-destructive testing
• Fault Fining and Maintenance Techniques

This Materials Selection and Failure Analysis training course will systematically offer information that can be used to analyze and implement several fault-finding techniques and relate them to the installation, performance, operation and inspection of mechanical systems and equipment.

By the end of this Materials Selection and Failure Analysis training course participants will be able to:

• Provide participants with the main failure mechanisms of equipment
• Introduce materials types and selection
• Attempt to maximize and customer satisfaction and performance of production equipment efficiently and, regularly, through high utilization of facility and adjusted and serviced equipment.
• Prevent breakdown or failures and minimize frequency and severity of interruptions.
• Maximize useful life of equipment and minimize production loss from failures.
• Increase reliability of the operating systems
• Keep equipment safe and prevent safety hazards

This Materials Selection and Failure Analysis training course is primarily intended for individuals who need to be familiarized with failure modes of mechanical equipment and the understand the methods of implementing fault finding methods and maintenance strategies and relating them to mechanical systems and equipment.

This Materials Selection and Failure Analysis training course is suitable to a wide range of professionals but will greatly benefit:

• General Engineers
• Plant Engineers
• Maintenance Personnel and Supervisors
• Technicians
• Other technical individuals

The training course will also benefit senior engineers and managers who would like to increase or refresh their knowledge in mechanical equipment damage, fault finding methods and maintenance topics.

This Materials Selection and Failure Analysis training course will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension and retention of the information presented. It will be conducted along workshop principles with formal lectures, case studies and interactive worked examples. Relevant case studies will be provided to illustrate the application of each tool in an operations environment. Each learning point will be re-enforced with practical exercises. There will be ample opportunities for discussion and sharing experiences.