Program Overview
Industries increasingly rely on pumps, valves, and rotating equipment that operate under corrosive, abrasive, high-pressure, or high-temperature conditions. When materials are mismatched to service requirements, failures escalate – leading to downtime, safety risks, and high replacement costs. This program equips engineering and maintenance teams with the knowledge to select the right alloys, interpret degradation patterns, evaluate coatings, assess metallurgical risks, and understand how fluid chemistry and operating loads affect long-term performance. Through practical cases and diagnostic exercises, participants learn how to improve component life, prevent failures, and strengthen equipment reliability across demanding industrial applications.
Features
- Select suitable materials for pumps, valves, and components based on service conditions
- Identify metallurgical failure modes and recommend corrective actions
- Evaluate advanced alloys, coatings, and treatments for improved performance
- Build reliable, cost-effective material recommendations that reduce failures and downtime
Target audiences
- Mechanical, metallurgical, reliability, and maintenance engineers
- Pump, valve, and equipment specialists
- Project, EPC, QA/QC, and supplier development engineers
- Senior engineers and emerging technical leads
Curriculum
- 4 Sections
- 25 Lessons
- 1 Day
- Metallurgy & Material Fundamentals5
- 1.1Carbon/alloy steels, stainless, duplex/super duplex, bronzes, nickel alloys, hard-facing alloys
- 1.2Critical properties: Hardness, toughness, yield strength, fatigue resistance, corrosion resistance, wear resistance
- 1.3Heat treatment effects on microstructure and service life
- 1.4Microstructural features: Grain size, carbide distribution, ferrite–austenite balance
- 1.5Manufacturing considerations: Weldability, casting quality, forgeability
- Degradation Mechanisms & Failure Modes7
- 2.1Corrosion forms: Pitting, crevice, uniform, SCC, intergranular, galvanic
- 2.2Erosion and slurry wear in high-velocity and abrasive services
- 2.3Cavitation damage and metallurgical indicators
- 2.4High-temperature effects: Oxidation, creep, thermal fatigue
- 2.5Failure patterns in shafts, impellers, casings, seats, discs, stems, bearings
- 2.6Material–media compatibility issues and accelerated degradation
- 2.7Influence of fluid chemistry on alloy performance
- Advanced Material Selection & Engineering Applications8
- 3.1Material selection for chemical plants, refineries, pharma utilities, HVAC, water treatment, offshore conditions
- 3.2Choosing between duplex, super duplex, and austenitic grades for chloride-rich or corrosive media
- 3.3Surface engineering: Stellite, tungsten carbide, HVOF coatings, overlay welding
- 3.4Upgrades to resist corrosion, erosion, and cavitation
- 3.5Case examples: CF8M → Duplex for high-chloride streams; Inconel/Monel for sour or high-temperature services
- 3.6Case Examples: Bronze, Ni-Al bronze, 316 variants for seawater; Chrome steels for abrasive slurries
- 3.7Supplier evaluation: MTC checks, NDE (RT, UT, PT, MT), hardness tests, PMI
- 3.8Balancing performance, lifecycle cost, and reliability
- Diagnostic Tools, Material Selection Exercises & Failure Simulations5
- 4.1Material compatibility evaluation for corrosive, slurry, and high-temperature media
- 4.2Failure analysis using sample images of pitting, SCC, cavitation, erosion
- 4.3Comparative material assessment (duplex vs. 316 vs. hard-facing alloy)
- 4.4MTC interpretation and compliance review
- 4.5Material selection simulation for a high-risk operating scenario
Instructor
