Metallurgy for Non- Metallurgists (Advanced)

Course Introduction

Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their inter-metallic compounds, and their mixtures, which are called alloys. It is used to separate metals from their ore, metallurgy is also the technology of metals: the way in which science is applied to the production of metals, and the engineering of metal components for usage in products for consumers and manufacturers. The production of metals involves the processing of ores to extract the metal they contain, and the mixture of metals, sometimes with other elements, to produce alloys.

During this interactive course, participants will learn the materials of construction used for the hydrocarbon processing and major utility sections of the plant; the chemical positions and properties of metallic materials; the iron-carbon phase diagram; the fabrication process for ferrous, non-ferrous and non-metallicmaterials; and the flow chart outlining the procedure for inspection of new materials.

Objectives

Upon completion of this training course, participants will have gained an in-depth understanding of the important principals of engineering involving properties and characteristics of metals and alloys, including fabrication and heat treatment of commercial steels and non-ferrous alloys.

By the end of the training, participants will be able to:

• Apply and gain an advanced knowledge on metallurgy engineering
• Review the materials of construction used for the hydrocarbon processing and major utility sections of the plant including piping, vessels, towers, valves and tanks
• Indicate the chemical positions and properties of metallic materials and discuss why these materials were used and how the mechanical properties were established
• Hand sketch the iron-carbon phase diagram and indicate the significant temperatures for phase changes and discuss the significance of carbon, chromium and nickel on the microstructure and mechanical properties of ferrous alloys
• Discuss the fabrication process for ferrous, non-ferrous and non-metallic materials
• Draw a flow chart outlining the procedure for inspection of new materials and provide an example of where this procedure has been applied
• Explain how this procedure is applied at the site and discuss any problems in may result in faulty material being used

Training Methodology

This interactive training course includes the following training methodologies as a percentage of the total tuition hours:-

• 30% Lectures, Concepts, Role Play
• 70% Workshops & Work Presentations, Techniques, Based on Case Studies & PracticalExercises, Software & General Discussions
• Pre and Post Test

Target Audience

This course is intended for all significant aspects and considerations of metallurgy for non- metallurgists who are involved in advanced metallurgy. The course is also intended for discipline- related graduates drawn from across the operating companies in the oil and gas industry in GCC.

Daily Topics

DAY I.

• PRE-TEST
• Introduction
• Oil Industry Materials
  • General Material Classifications (Metals, Ceramics, Polymers, Composites)
  • Structure of Materials, Solid State Structure, Primary Metallic Crystalline Structures
  • Chemical and Physical Properties
• Mechanical Properties and Material Testing
  • Mechanical Properties, Loading, Stress and Strain, Tensile Properties, Compressive, Bearing, & Shear Properties, Hardness, Creep and Stress Rupture Properties, Toughness, Fatigue Properties, Effect of Mechanical Properties of Pressure Vessels Material on Allowable Operating Pressure and Wall Thickness
• Alloying and Phase Diagrams
  • Property Modification, Alloying, Composition, Microstructure, and the Phase Diagram
  • The Allotropy of Iron, The Iron Carbon Equilibrium Diagram

DAY II.

• Heat Treatment
  • Common Heat Treatments, Annealing, Normalizing, Tempering, Hardening, Carburizing,Nitriding, Quench Media, Stress Relieving
• Ferrous and Nonferrous Alloys
  • Steel Alloys, Effects of Elements on Steel, Stainless Steels, Aluminum Alloys, Copper Alloys,Nickel alloys, Titanium Alloys, Typical Alloys used in Oil & Gas Industry & their Applications
• Materials Specification
  • Codes and Standards
• Recap - Using this Course Overview, the Instructor(s) will Brief Participants about the Topics thatwere Discussed Today and Advise Them of the Topics to be Discussed Tomorrow

DAY III.

• Commercially Available Alloys
  • Standards, Codes & Nomenclature, Composition & Equivalent
  • Physical & Mechanical Properties, Basis of Selection
  • Case Studies Examples from Am, Urea & Utilities
• Metals and Alloys Selection for Use in Different Environments
  • Hydrogen and Hydrogen Sulfide Corrosion, Oxidation or Scaling and Stack Gas Corrosion,Seawater, Water and Soils and Biological Corrosion, Corrosion by Mineral Acids and Alkalies, Organic Acids and Carbon Dioxide, Atmospheric Corrosion, Disbanding ofAustenitic Stainless Cladode Steels, Behavior of

Chromium - Nickel Steels in SpecialCorrosive Media

• Material Selection and Design Considerations
  • Introduction
  • Utilization of Material Information
  • Utilization of Material Properties
  • Using of Codes and Standards
• Recap - Using this Course Overview, the Instructor(s) will Brief Participants about the Topics thatwere Discussed Today and Advise Them of the Topics to be Discussed Tomorrow

DAY IV.

• Heat Treatment of Plain Carbon Steel
  • Hardening of Carbon Steel (by quenching), Annealing, Normalising, Tempering, Austempering, Surface Treatments, Heat Affected Zone (HAZ) in Welding, Non-Ferrous Alloys, Nickel and Cobalt, Titanium Alloys
• Case Studies / Practical Exercises

DAY V.

• Corrosion in Metals
  • The Electrochemical Cell, Types of Electrochemical Corrosion, Pitting, Crevice, StressCorrosion, Hydrogen Induced,
• Protection Against Electrochemical Corrosion and Inspection
  • Coatings, Internal, External, Polymers, Galvanizing, , Inhibitors, Types and Usage,Cathodic Protection, Impressed Current, Sacrificial, Inspection, Standards
• Course Conclusion
• POST-TEST and EVALUATION

For registration & more information please contact

NAYEL Training Centre 

T: +971 4 379 7245 | M: +971 50 249 6876 WhatsApp +971 50 249 6876

Email [email protected]