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API 571 Certification Preparation

“Damage Mechanisms Affecting Fixed


Equipment in the Refining Industry”

INTRODUCTION OBJECTIVES

This course prepares the student for the API RP 571 The course provides participants with the knowledge
examination (Damage Mechanisms Affecting Fixed Equipment in necessary to:
the Refining and Petrochemical Industries). The course is an
intensive one week course covering the 64 corrosion ⇒ Successfully pass the API RP 571 ICP exam.
mechanisms documented in the API 571. It will also review basic ⇒ Understand the subject matter on the API 571
refinery flow as needed to understand how the flow affects exam.**(Steel-Solutions guarantee).
corrosion mechanisms. ⇒ Have a detailed background on the scope, organi-
zation and use of API RP 571.
This API 571 Supplemental Inspection Certification Program (ICP)
⇒ Understand the relationship between various cor-
is designed to train inspectors on damage mechanisms affecting
rosion mechanisms and associated metallurgy.
fixed equipment in the refining industry. The objective of the
ICP is to provide documented evidence of advanced knowledge ⇒ Identify various inspection techniques for the dif-
and expertise (above the basic core API 510, 570 & 653 ferent metallurgies and corrosion mechanisms.
examinations) in the area of Corrosion and Materials based on ⇒ Comprehend how various corrosion mechanisms
the information contained in API RP 571. Completion of the API react in specific environments (how they can be
ICP 571 will add significant value to your professional creden- rate controlled).
tials. It will show your employers and clients that you have ⇒ Understand general damage mechanisms applica-
obtained a high level of proficiency and understanding in this ble to the refining industry and be able to identify
important field. their features & functions.

The importance of the API 571 certification is that it is a key first .


step in safely and reliably. Proper identification of damage
mechanisms is important when:
⇒ Implementing the API Inspection Codes (API 510, 570 &
653).
⇒ Conducting risk based inspection per API 580 / 581. WHO SHOULD JOIN
Methodologies for Risk-Based Inspection (RBI) depend
on the accurate prediction and determination of active Students should have in petrochemical industry experience.
mechanisms. This is an INTENSIVE class that is designed for plant inspec-
⇒ Performing a fitness-for-service assessment using API tors, mechanical engineers, process engineers, and opera-
579. The damage mechanisms need to be understood tors who are involved in inspection, RBI, FFS, and fixed
and need to be considered when evaluating the re- equipment reliability programs. Familiarity with Non De-
maining life. structive Testing (NDT) is a real advantage. Although refin-
⇒ Setting up effective inspection plans requires an in- ery problems are the main focus of the classes, personnel
depth understanding of what kind of damage to look from related industries (such as mid-stream companies, gas
for and how to identify it. . plants, and petrochemical firms) also benefit from the
⇒ Conducting an MOC. An effective Management of course content and exercises.
Change (MOC) process needs to consider the effect of Any Inspector or Engineer interested in the refinery corro-
proposed changes on future degradation.· Many prob- sion area can attend the class, however, API requires any-
lems can be prevented or eliminated if the precursors one that is going to take the test be currently certified as
to damage are observed and monitored so that any an API 510, 570 or 653 Inspector.
potential damage is mitigated.

Organized by:

594752 (M)
HRD Approved Training Provider (AO470)
Ministry of Finance (Reg. No 357-02088676) Updated on 14 Jan 2010
API 571 Certification Preparation
“Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry”

SPEAKER’S BACKGROUND ABOUT THE RUST BUSTERS

The Rust Busters is a company specializing in providing


Marc McConnell is a Chemical Engineer with 30 years
the Oil and Gas industry with API Certification Training,
as an owner-user and consultant to refining and
chemical process industries. He holds multiple Corrosion related Training, Operations Documentation,
patents in process technology and distributed control. Data Interpretation, and Consulting services.
Most of these applications are related to the
mitigation of corrosion related parameters in the The Rust Busters were formed by mutual friendship
refinery. He has been involved in corrosion reviews between an Inspector and an Engineer. We realized the
for API’s Risk-Based Inspection projects, and recently advantages that each brought to the petroleum and
focused on corrosion problems in hydro-processing chemical process industries. Each asked the other
process units where his specialty is in wash water questions that were not readily explained.
design of Reactor Effluent Air Coolers (REACs).
The Inspector asked and learned the WHY...
He recently co-authored an Risk Based Inspection (RB) The Engineer asked learned the HOW...
I presentation at NACE (National Association of
Corrosion Engineers) Corrosion Technology resulting in a unified approach uncommon in the
Week/2006 (Refining State of the Art). He is slated to industry. Our training courses reflect the same synergy.
present a paper at the NACE International Convention
The Rust Busters is rich with its resources and hands-on
2010 on IR(infra red) use for corrosion control /
-experience.
identification.

Marc is a contributing author on the current re-write


of API RP 571. This is being done to Update/Revise/ Our Teaching Philosophy
Clarify the existing RP-571 document.
We believe in the old motto,
Current Certifications include
⇒ Licensed Texas Professional Engineer “If the student didn’t learn, the teacher didn’t teach”
⇒ API 510 – Pressure Vessel Inspection Code
⇒ API 571 – Damage Mechanisms in Our goal is comprehension rather than memorizing
Refining Industry answers on the tests. We want you to be successful,
⇒ API 577 - Welding Inspection and and for your knowledge to make our industry a safer
Metallurgy place to work.
⇒ API 580 – Risk Based Inspection

Organized by:

594752 (M)
HRD Approved Training Provider (AO470)
Ministry of Finance (Reg. No 357-02088676) Updated on 14 Jan 2010
API 571 Certification Preparation
“Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry”

COURSE SCHEDULE DAILY SCHEDULE ( 5 1/2 Days Class)


8:00am – 5:30pm (Workshop)
Day 1 6:30pm – 8:30pm (Optional evening study sessions)
Introduction Module 0
Note: This course will have daily homework and a final exam
The API 571 Test Overview Module 1 (similar to the API 571 exam)
Refinery Materials of Construction Module 2
Stress Corrosion Cracking (SCC) Module 3
CLASS SIZE
Day 2
Enrollment is limited to 25 students.
High Temperature Corrosion Module 4
Refining Units Module 8
BRING TO CLASS
Day 3 Students should bring to class: a calculator, a straight edge (or
High Temperature Corrosion (cont’d) Module 4 triangle), pencils, highlighters, lots of questions, and a “CAN-
Refining Units Module 8 DO” attitude.

Also, participants must bring the appropriate codes


Day 4
required for the API exam.
General Damage Mechanisms – All Industries Module 5
Uniform or Localized Loss of Thickness Module 6
Refining Units Module 8
MODULE 1 The API 571 Test Overview

Day 5 Introduction
General Damage Mechanisms – 1. What to bring
Refining Industry Module 7 2. What to expect
3. How to prepare
Refining Units Module 8

MODULE 2 Refinery Materials of Construction


Day 6
Tips on taking the test Module 9
The Test Part I (Introduction) Part II
1. Steel 8. How Steel and Cast Iron
2. Carbon Steel Differ
3. Cast Iron 9. Stress Relieving
4. C-MoSteel 10. Annealing and normalizing
5. Cr-Mo Steels 11. Dehydrogenation
6. Killed Steel
7. Stainless Steels

Organized by:

594752 (M)
HRD Approved Training Provider (AO470)
Ministry of Finance (Reg. No 357-02088676) Updated on 14 Jan 2010
API 571 Certification Preparation
“Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry”

MODULE 3 Stress Corrosion Cracking (SCC) MODULE 5 General Damage Mechanisms - All Industries

Environmental - Assisted Cracking 1. Steam Blanketing


1. Chloride SCC 2. Dissimilar Metal Weld Cracking
2. Corrosion Fatigue 3. Thermal Shock
3. Caustic SCC (Caustic Embrittlement) 4. Erosion / Erosion – Corrosion
4. Ammonia Stress Corrosion Cracking 5. Cavitation
5. Liquid Metal Embrittlement (LME) 6. Mechanical Fatigue
6. Hydrogen Embrittlement 7. Vibration – Induced Corrosion
7. Polythionic Acid SCC 8. Refractory Degradation
8. Amine SCC 9. Reheat Cracking
9. Wet H2S Cracking 10. The mechanics of corrosion mechanisms
a. Hydrogen Induced Cracking (HIC)
b. Stress Orientated HIC (SOHIC)
c. Sulfide SCC (SCC) MODULE 6 Uniform or Localized Loss of Thickness
10. Hydrogen Stress Cracking – HF
11. Carbonate SCC 1. Galvanic Corrosion
2. Atmospheric Corrosion
3. Corrosion Under Insulation (CUI)
4. Cooling Water Corrosion
5. Microbiologically Induced Corrosion (MIC)
MODULE 4 High Temperature Corrosion 6. Dealloying
7. Graphitic Corrosion
High Temperature Corrosion (400 + F) 8. Boiler Water condensate Corrosion
9. CO2 Corrosion
1. Sulfidation 11. Strain Aging 10. Flue Gas Dew. Point Corrosion
2. Carburization 12. 885 F Embrittlement 11. Soil Corrosion
3. Decarburization 13. Sigma Phase Embrittlement 12. Caustic Corrosion
4. Metal Dusting 14. Brittle Fracture
5. Oxidation 15. Creep / Stress Rupture
6. Fuel Ash Corrosion 16. Thermal Fatigue
7. Nitriding 17. Short Term Overheating – API APPLICATION
8. Graphitization Stress Rupture
9. Softening (Spheroidization) The scheduled dates for API 571 Inspector Certification
10. Temper Embrittlement
Examination is as below:

API INFO
API 571
The API Web-site offers some useful information
(i.e. application form, sample test question, required code API 571
books). Here’s the web-site that takes you directly to the data. API 571
www.api.org/icp

Organized by:

594752 (M)
HRD Approved Training Provider (AO470)
Ministry of Finance (Reg. No 357-02088676) Updated on 14 Jan 2010
API 571 Certification Preparation
“Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry”

MODULE 7 General Damage Mechanisms MODULE 8 Putting it All Together - Process Units
- Refining Industries
1. Crude Unit / Vacuum
1. Amie Corrosion 2. Delayed Coker
2. Ammonium Bisulfide Corrosion (Alkaline Sour Water) 3. Fluid Catalytic Cracking (FCC)
3. Ammonium Chloride Corrosion 4. FCC Light Ends Recovery
4. Hydrochloric Acid (HCl) Corrosion 5. Catalytic Reforming (CCR)
5. High Temp H2/H2S Corrosion 6. Hydroprocessing Units – Hydrotreating / Hydrocracking
6. Hydroflouric (HF) Corrosion 7. Sulfuric Acid Alkylation
7. Naphthenic Acid Corrosion 8. HF Alkylation
8. Phenol (Carbonic Acid) Corrosion 9. Amine Treating
9. Phosphoric Acid Corrosion 10.Sulfur Recovery
10. Sour Water Corrosion (Acidic) 11.Sour Water Stripper
11. Sulfuric Acid Corrosion 12.Isomerization
13.Hydrogen Reforming

MODULE 9 The Test

HOTEL ACCOMMODATION INFORMATION

Hotel Single Distance


SinggahSana Hotel
3 stars www.hspj.com.my RM 115 About 10 mins
Tel:(603)-7956 2100

Shah Village Hotel


3 stars www.shahsresorts.com RM 150 About 10 mins
Tel:(603)-7956 9322

Armada PJ Hotel
4 stars www.armada.com.my RM 167 By train; one station away
Tel :(603)-7954 6888

Hilton PJ Hotel
5 stars www.hilton.com RM 345 About 15 mins
Tel :(603)-7955 9122

* Room rate is subject to change if the needs arise from the hotel.

Organized by:

594752 (M)
HRD Approved Training Provider (AO470)
Ministry of Finance (Reg. No 357-02088676) Updated on 14 Jan 2010