ICTD International Centre for Training and Development

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

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About the course

The course enables delegates already familiar with what concrete is, to develop skills in 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 reinforced concrete structure without shut down the plant. The advanced inspection methods for fresh and hardened concrete will be discussed and how to implement maintenance plan for all the concrete structure.

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 its lifetime.

The objective of this course is to introduce causes of damaged R.C. structures. Factors affecting 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 already familiar with what concrete is, to develop skills in effective specification, production and end users of concrete. The course also covers basics as well as advanced concepts up-to-date technology.

The course will illustrate up to date modern technique to repair the reinforced concrete structure without shut down the plant. The advanced inspection methods for fresh and hardened concrete will be discussed and how to implement maintenance plan for all the concrete structure.

Course Objectives

Upon successful completion of this course, the delegates 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 an d reinforced concrete structures as well as their effects in the assessment and rehabilitation of the structures
  • Determine the causes of concrete and reinforced concrete structure damage and identify the additional preventative measures being applied in concrete structures
  • Implement the latest methodology of damage assessment including the identification of service and exposure conditions of concrete structures
  • Carryout assessments of corrosion affected structures and explain the assessment of the reinforced concrete structures 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 systems 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
  • The participants will be provided with detailed course material and will be familiarized with various features on concrete construction in petroleum projects
  • The engineer will be familiar with any problem and its solution in the concrete structure in the petrochemical industry and its causes of failure

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
  • Pipes Loads on Pipe Rack
  • Different between ACI and BS in Design
  • Pipeline Support Design

Day 2

  • 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 the Steel Bars
  • CP system for Steel Protection
  • Advanced Method of Steel Protection
  • Design the CP System
  • Ways of Inspection the Concrete Structures
  • Diagnosis the Problems in Concrete Structures
  • Reasons of Fails and Cracks of Concrete Structure in Process Plant
  • Case Studies from Petrochemical Plants
  • Case Studies from General Industries

Day 4

  • Inspection and Quality Control of Concrete
  • Sampling and Testing Concrete on Site
  • Methods of Test the Corrosion
  • Measuring the Corrosion Propagation
  • Concrete Structure Evaluation
  • Ways of Repair the Concrete Structure
  • Effective Supervision of Repairs
  • Selection of Materials — Cements, 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 a Steel Sections
  • CFRP for Repair
  • Principal of CFRP Design
  • Integrity Management System

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is intended for 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.

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