Summary:

This course focuses on how to avoid component failures on steam methane reformers used in ammonia, methanol and hydrogen plants.

One of the biggest fears for owners of ammonia, methanol and hydrogen plants is a significant failure event on the heart of the plant, the Steam Methane Reformer (SMR). This training reviews failures and near misses on 40 SMR’s, located in eleven countries globally. The intent of this training is to provide insight into:

• What damage mechanisms have historically led to failures on SMR components.
• What critical design, construction and operating controls were absent which allowed these damage mechanisms to occur.
• What preventative measures (controls) need to be put into place to prevent these failures from occurring on your steam methane reformer. 

This training also provides a methodology for completing a detailed analysis of your SMR to ascertain what components have weak or absent controls and consequently are most at risk of becoming the next significant unplanned plant outage.  

Outline:

• Summary of failure events on 40 steam methane reformers
• Inlet loop failures and damage mechanisms
• Catalyst tube failures and damage mechanisms
• Outlet loop failures and damage mechanisms
• Transfer Lines / Cold Collector failures and damage mechanisms
• Convection Section failures and damage mechanisms

Who Should Attend:

• Process Engineers, Senior Operators, Integrity Engineers, Reliability Engineers and Inspectors, focused on the operation and reliability of steam methane reformers.
• Project Engineers tasked with the design, construction and fabrication of steam methane reformer components such as catalyst tubes, manifolds, pigtails, convection coils and piping systems.

Instructors: 

David Keen is a qualified Metallurgist with over 46yrs domestic and international experience in Syngas manufacturing facilities. David is a Subject Matter Expert (SME) on fixed equipment integrity management and has in recent years downloaded this knowledge into a series of training modules focused on preventing equipment failures through experiential learning and team problem solving sessions. He has held various positions including Global Company Chief Engineer, VP Global Reliability & Risk, Company Engineer Fixed Equipment, Reliability Manager, Operations Manager, Maintenance Manager, T/A Manager and Plant Metallurgist. David has worked as a consultant to Hydrogen, Ammonia and Methanol plants in 12 countries globally. He has been involved in implementing RBI programs, IOW programs, auditing fixed equipment management, completion of failure investigations, root cause analyses, fixed equipment repairs and design and construction of new fixed equipment. David has worked on 33 steam methane reformers and is a recognized subject matter expert in the integrity management of SMRs.

Venkat Pattabathula is a highly experienced Subject Matter Expert in ammonia, hydrogen, and energy transitions, with over 40 years in process engineering and project management. He has led diverse projects, from small-scale to mega-projects, across various regions, including Asia, North America, and Australia. Venkat’s expertise spans feasibility studies, technology evaluation, optimization, and energy transitions, with a strong focus on ammonia, urea, and hydrogen production. A chartered engineer with Engineers Australia and a member of AIChE's Ammonia Safety Committee since 2005, Venkat has published over 140 papers and contributed a chapter on "Ammonia" for the Kirk-Othmer Encyclopedia. His educational background includes a postgraduate degree from IIT and a certificate from MIT. His consultancy, SVP Chemical Plant Services, provides technical services to the global hydrogen, ammonia, and urea industry.

Training Location:  

Level 1, 320 Adelaide Street, Brisbane Queensland 4000

*There is no designated hotel for this training. Discounted hotel options to come.

Summary & Outline: 

Most pressure equipment and piping failures in syngas and hydrocarbon plants occur in or adjacent to welds. Why is this so?

The next two days focus on how to avoid component failures resulting from sub-optimal welding, fabrication and repair procedures and practices. Practical exercises are also included to ensure attendees are able to convert theory into practice.  

• Practical overview of welding
• Metallurgy of Welding Steels and Alloy Steels
• Metallurgy of Welding Stainless Steels
• Material Properties
• Welding and Fabrication – prevention of high temperature damage mechanisms
• Welding and Fabrication – prevention of corrosion / stress corrosion damage mechanisms
• Welding Processes, Terminology and Symbols
• Welding Defects
• Welding Steels and Alloy Steels
• Welding Austenitic Stainless Steels and Nickel-based materials
• Practical Exercise: Developing Fabrication Design and Construction Datasheets
• Practical Exercise: Replacing a Carbon Steel Heat Exchanger with a Duplex Stainless Steel (tube) Heat Exchanger

Who Should Attend:

Integrity Engineers, Reliability Engineers, Project Engineers and Inspectors, focused on the design, construction, fabrication and repair of pressure equipment, including process vessels, heat exchangers, reformer and furnace components, tanks and piping systems.

Instructors: 

David Keen is a qualified Metallurgist with over 46yrs domestic and international experience in Syngas manufacturing facilities. David is a Subject Matter Expert (SME) on fixed equipment integrity management and has in recent years downloaded this knowledge into a series of training modules focused on preventing equipment failures through experiential learning and team problem solving sessions. He has held various positions including Global Company Chief Engineer, VP Global Reliability & Risk, Company Engineer Fixed Equipment, Reliability Manager, Operations Manager, Maintenance Manager, T/A Manager and Plant Metallurgist. David has worked as a consultant to Hydrogen, Ammonia and Methanol plants in 12 countries globally. He has been involved in implementing RBI programs, IOW programs, auditing fixed equipment management, completion of failure investigations, root cause analyses, fixed equipment repairs and design and construction of new fixed equipment. David has worked on 33 steam methane reformers and is a recognized subject matter expert in the integrity management of SMRs.

Training Location:  

Level 1, 320 Adelaide Street, Brisbane Queensland 4000

*There is no designated hotel for this training. Discounted hotel options to come.