Design, Inspection, Repair and Maintenance Concrete Structure in Petrochemical Plants

Introduction

The course enables delegates already familiar with what concrete is, to develop skills in the effective specification, production and end-users of concrete. The course also covers basics as well as advanced concepts up-to-date technology and techniques to the reinforced concrete structure without the shutdown of the plant. The advanced inspection methods for fresh and hardened concrete will be discussed and how to implement the maintenance plan for all the concrete structures. The integrity management system procedure will be illustrated taking into consideration the major factors in design, construction, and repair to maintain the concrete structure economically in all at its lifetime. The objective of this course is to introduce the causes of damaged R.C. structures. Factors affecting the corrosion of concrete and reinforcing steel will be explained. Repairing materials and techniques will be discussed. This course is intended for civil engineers who are interested in the area of inspection, assessment, and repair of concrete structures in petrochemical plants. This course enables delegates who are already familiar with what concrete is, to develop skills in the effective specification, production, and end-users of concrete. The course will illustrate up to date technique to repair the reinforced concrete structure without the shutdown of the plant. The advanced inspection methods for fresh and hardened concrete will be discussed and how to implement a maintenance plan for all the concrete structures.

Objectives

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

• Design, inspect, repair and maintain concrete structures in petrochemical, plants
• Identify the layout of process equipment in the petrochemical plant
• Design the footing and foundation for several process equipment such as compressors, turbines, pumps, motors, pressure vessels, heat exchangers, boilers and distillation columns
• Design reinforced concrete tanks as well as the supports/anchor blocks of pipelines/piping system
• Design the foundations and structures of furnaces, process fired heaters and process reactors
• Identify the various types of damage that can affect concrete and reinforced concrete structures as well as their effects in the assessment and rehabilitation of the structures
• Determine the causes of concrete and reinforced structure damage and identify the additional preventative measures being applied in concrete structures
• Implement the latest technology of damage assessment including the identification of service and exposure conditions of concrete structures
• Carry out assessments of corrosion affected structures and explain the assessment of the reinforced structure concrete structure conditions
• Repair and rehabilitate concrete structures including methods to prevent defects in concrete, rehabilitation methods against corrosion damage and determine the required properties of repair materials and system in concrete structure
• Implement a risk-based maintenance strategy with the required repair time, required time to start of corrosion and deterioration as well as cost analysis for different protection methods
• Become familiarized with various features on concrete construction in petroleum projects
• Become familiar with any problem and its solution in the concrete structure in the petrochemical industry and its causes of failure

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This course is intended for all the Design Engineers, Inspection Engineers, Maintenance Engineers, Civil Engineers, Integrity Engineers, Construction Engineers, Material Engineers, Maintenance Technicians and Inspectors responsible for the integrity and maintenance of reinforced concrete structures in petrochemical plants.

Course Outline

Day 1: Introduction

• Loads that Affect the Structures

• Loads that Affect the Pipe Rack, Tanks

• Dead Load and Live Load

• Wind Load and Seismic Load

• Pipe Loads on Pipe Rack

• Different between ACI and BS in Design

• Pipeline Support Design

Day 2:

• The principal of Design Foundation under Machine

• Concrete Tanks in Gas Processing

• Design of Foundation Under (Separator, Kod, Static Equipment)

• Concrete Production and Quality Assurance

• Concrete Properties

• Portland Concrete, Slag, and Fly Ash Properties

• Properties of Admixtures and Concrete Mixes

• Principles of Concrete Mix Design

• Inspection, Sampling and Compliance Testing

• Corrosion Problem Onsite

Day 3:

• Protection of Steel Bars from Corrosion

• Advanced Technique to Protect Steel Bars

• CP System for Steel Protection

• Advanced Method of Steel Protection

• Design the CP System

• Ways of Inspection the Concrete Structures

• Diagnosis of the Problems in Concrete Structures

• Reasons for Fails and Cracks of Concrete Structure

• Case Studies from Petrochemical Plants

• Case Studies from General Industries

Day 4:

• Inspection and Quality Control of Concrete

• Sampling and Testing of Concrete on the Site

• Methods of Testing the Corrosion

• Measuring the Corrosion Propagation

• Concrete Structure Evaluation

• Ways of Repair the Concrete Structure

• Effective Supervision of Repairs

• Selection of Materials – Cement, Aggregates, Additions, and Reinforcement

• Concrete Mixes and Specifications in Repair

• Methods of Repair Slabs, Beams, Columns and Foundations

• Best Ways of Using Epoxy in Repair

• Case Study for Repair Ring Beam for Tanks

• Case Study for Repair Foundation

DAY 5:

• New Modern Method for Repair

• Repair by Using Steel Sections

• CFRP for Repair

• The principal of CFRP Design

• Integrity Management System