Book and pay before 25 September 2016 to save up to SAR 2000!

2-Days INTERNATIONAL TECHNICAL MEETING - 16-17 October 2016

+ 2 Days TRAINING on P91 & P92 Steels - 18-19 October 2016
Venue: Intercontinental Hotel AL-JUBAIL SAUDI ARABIA

Key Confirmed Speakers

1st International Technical Meeting

High Temperature Plant Issues (HTPI)

Dr Ahmed Shibli Engr Saeed Bayounis Prof Dr Fujimitsu Masuyama,

Managing Director President Dept. of Materials Science and
ETD Consulting, UK SAHARA Petrochemicals Engineering, Kyushu Institute
Jubail Saudi Arabia of Technology, Japan

Ms. Sumah Hamad

Henryk Mazur, Dr Wajid Ali Khan Operational Excellence
Director Professor Management System Leader
Mazur Energy, University of Hafr Al Batin BAPCO, Bahrain
Poland Saudi Arabia

Dr. Faheem Hashmi

Prof and Founding
Dr David Robertson Alexandros Antonatos Director
Lead Metallurgist Public Power Corporation Failure Analysis Center
ETD Consulting, UK of Greece, Greece IST, Islamabad, Pakistan

Engr. Saleh Al-Mozaai

Stephen Newcomb RCA Engineer
Engr S.Nadeem Ahmed
Technical Manager Water & Electricity Company
Independent Consultant
SAHARA Petrochemicals Riyadh Saudi Arabia
Doha Qatar
Jubail Saudi Arabia

Dr. Abdulaziz Almathami Attiah Hasan Al-Zahrani

Qurban Ali Lashari R&D Manager Staff Reliability Engineer
Corrosion Engineer Baker Hughes TASNEE, Jubail
Saudi ARAMCO, KSA DGTC Dahran KSA Saudi Arabia
 Why This Technical Meeting?
This conference will bring
together CEOs, Vice Presidents,
Directors, Managers, Engineers,
The pace of change in power, petrochemicals, refining, fertilizers and process and Inspectors from:
plant sectors has never been faster with continuing improvement in plant and
Asset Life Cycle Management
component design and construction procedures and a move from traditional
Emergency Repair Section
low alloy steels (such as 2.25Cr1Mo) to higher strength higher alloy materials
Electricity Operation and
(such as P91, P92 and P93) that can withstand higher temperatures and Maintenance
pressures. All of this in an effort to increase output, efficiency and flexibility Reliability and Maintenance
and to reduce pollution and associated penalties. Inspection
Corrosion
New NDE techniques and methodologies have also been developed over the
Manufacturing
past few years to monitor and inspect components in an effort to predict and
Production Department
assure the integrity and life of critical power and process plant components. Health, Safety and Environment
Similarly new codes and standards are being established in Europe, Japan and Assets Integrity
USA for RBM/ RBI, Fitness-For-Service (FFS), weld repairs (including cold weld Operations
repairs) and life assessment (to name only a few). Water Projects and Maintenance

Furthermore, new methodologies are being developed and demonstrated for

the benchmarking and O&M cost determination of both the conventional and
CCGT plants.

Intervention of renewables such as wind and solar, which can literally fall off within minutes, means that the conventional
plants have to be ready to brought back into full operation at a very short notice. This has necessitated the design and
operation of power plants to withstand damage when starting up at a very short notice. Thus in addition to creep, fatigue
has now also become a dominant factor in determining the safe operating life of existing power plants.

Risk based maintenance (RBM) is now becoming a common feature of many industries including power and process plant
as it essentially reduces the cost of inspection without reducing the risk. Similarly Reliability Centered Maintenance (RCM)
is now also finding more favor with many type of industries, including power and process industries.

Some of the above and related topics will be discussed at this meeting.

Papers/ Presentations and Meeting Proceedings: As this is primarily an industry led Technical Meeting some
industry experts may not be interested in offering full papers. In that case their presentations in PDF
format will be published in the electronic version of the Meeting Proceedings which will be provided to
the attendees within a couple of weeks of the holding of the Conference.
 About the Organizers

AMCO Saudi Arabia

AMCO provides best Metallurgical Services to Saudi Arabian Oil and Gas, Petrochemical, Power Generations, Fertilizers,
Refineries, Manufacturing, Construction, Manufacturing, Defense and Automobile Industries.

AMCO is a highly innovative Metallurgical, Engineering Service provider and Consulting Company, offering technical
support services to clients. The company works through a corporate model of core staff and a pool of internationally
known technical experts with practical experience, background and expertise in power, petrochemical, refining, fertilizer,
oil & gas and process plant.

Our specialization is: Plant Life Assessment /Extension, Failure Investigation, Asset Integrity Management, Plant Cycling,
Crack Assessment, Risk Based Inspection/Maintenance, Probabilistic Assessment, Fitness-for-Service Assessment,
Conditional Assessment, Plan Reliability Studies, Vibration Analysis, Stress Analysis, Support and guidance in Plant
Operation and Maintenance; Advice in weld repairs; Support with Materials, Inspection and Monitoring; Corrosion and
oxidation issues, Bench-Marking, Technology Development, Finite Element Analysis with years experience around the
globe.

European Technology Development (ETD)

European Technology Development (ETD) is a UK based engineering advisory, consulting and R&D Company specializing
in high temperature plant life assessment/extension, maintenance, materials and engineering issues in all type of power
generating and petrochemical/ process plant. Consulting is the core business of ETD. ETD has been organizing for nearly
two decades various international workshops/ courses/ conferences in Europe, USA and Asia mainly on the issues such
as: industrial plant life assessment/extension, high temperature plant materials, plant component safety and durability,
performance of in-service welds, power plant cycling, risk based maintenance (RBM), probabilistic assessment, weld
repairs etc. The company has been leading and coordinating a number of large leading edge international industry
initiatives (supported by the industry from North America, Japan, Europe and elsewhere or by government organizations
such as the European Commission) on issues related to the assessment and improvement of high temperature plant
performance, materials and design, maintenance and inspection strategies. Further information about ETD, its projects,
life assessment courses offered and other activities can be seen at: www.etdconsulting.com In the past ETD has organized
a number of conferences, seminars and Training Courses in London, Germany, Portugal, France, USA, Japan, Middle East,
Africa and South East Asia on P91, P92, P23 and P24 issues. ETD has furthermore published a number of guidelines and
review reports on these issues for its international industry sponsors.

Sponsorship and Exhibition Opportunities

This international meeting is expected to be attended by plant operators, manufacturers,
researchers, steel producers and service providers, particularly from Saudi Arabia. Thus it will be a
great opportunity for the exhibition of your products/ services. For information and costs involved
please contact: Mr. Ansar Hayat : mat1@amco-consult.com
 MEETING DAY ONE
Sunday, 16 t h October 2016

08:30 Registration and Coffee

09:00 Welcome by AMCO Team

Session 1:

Welcome Speech
Abdullah Al-Shammari, President, AMCO Company Ltd, Saudi Arabia 0900- 0905h

Guest Speaker Speech

Engr. Saeed Bayounis, President, SAMAPCO (SAHARA) Petrochemicals, Saudi Arabia 0905- 0920h

Plenary Paper
1. History of the development of alloys for high temperature plant
Prof Dr Fujimitsu Masuyama, Dept. of Materials Science and Engineering, Kyushu Institute of
Technology, Japan
(Previously chief researcher, Mitsubishi Heavy Industry, Nagasaki and inventor of some of the new
generation of steels) 0920- 1010

Tea Break 1010 1040h

Plenary Paper
2. Aberrant P91 steel and development cum demonstration of new NDE techniques and
methodologies for inspection, monitoring and life assessment of critical components
Dr Ahmed Shibli, Director, ETD Consulting, Surrey, United Kingdom 1040- 1130h

3. P91 and P92 material quality control from mill production through fabrication to plant
erection
Henryk Mazur, Managing Director, Mazur Energy, Poland 1130- 1200h

Lunch Break 1200 1300h

 Session 2:

Keynote Paper
4. Life assessment and extension of power plant boilers and HRSGs
Dr David Robertson, Lead Metallurgist, ETD Consulting, Surrey, United Kingdom 1300- 1340h

5. Experience with dissimilar metal welding of P91 steel with low alloy steels
Alexandros Antonatos, Public Power Corporation of Greece, Greece 1340- 1410h

6. Corrosion under Insulation, shielding, and inspection techniques

Qurban Ali Lashari, Corrosion Engineer, Saudi ARAMCO, Dahran, Saudi Arabia 1410- 1440h

Tea Break 1440 1510h

7. High Temperature Sulfidic Corrosion in Desulfurizing Units - Failures & Preventions

Qaisar Abbas, Reliability & Inspection Engineer, Saudi Arabian Fertilizer Company (SAFCO) - A
SABIC Affiliate, Jubail Saudi Arabia 1510- 1540h

8. A comparison of different joining options of hybrid composite joints for better fatigue life
Dr Amjad Ali Khan, Department of Mechanical Engineering University of Hafr Al Batin,
Al-Batin, KSA 1540- 1610h

9. Critical success of Root Cause Analysis

Attiah Hasan Al-Zahrani, Staff Reliability Engineer, TASNEE Complex, Jubail Saudi Arabia
1610- 1640h

Panel Discussion - 1640 to 1700h

 MEETING DAY T W O
Monday, 17 October 2016
08:30 Welcome by AMCO Team

Session 3:

Plenary Paper
1. ASME P93 steel New miracle 9Cr martensitic steel
Prof Dr Fujimitsu Masuyama, Dept. of Materials Science and Engineering, Kyushu Institute of
Technology, Japan 0830- 0920h

Keynote Paper
2. Reliability Centered Maintenance (RCM) for power and process plant
Syed Nadeem Ahmed, Independent Consultant,, Doha, Qatar 0920- 1000h

Tea Break 1000 1030h

3. A Case Study for Implementing Strategies to Address High Temperature Damage Issues
Stephen Newcomb, Technical Manager, SAHARA Petrochemical Plant, Jubail, Saudi Arabia
1030- 1100h

4. How to build reliable people in field?

Engr. Saleh Al-Mozzai, RCA Engineer, Water and Electricity Company, Riyadh, Saudi Arabia
1100- 1130h

5. Application of Fracture Mechanics in Power Plant Integrity Assessment

Dr. Fahim Hashmi, Founder, Failure Analysis Center (IST Pakistan), Islamabad, Pakistan
1130- 1200h

Lunch Break 1200 1300h

 Session 4:

Keynote Paper
6. Assessment of cracks in industrial components according to the international codes and
procedures
Dr Ahmed Shibli, Director, ETD Consulting, Surrey, United Kingdom 1300- 1340h

7. Condition assessment of power plants

Dr David Robertson, Lead Metallurgist, ETD Consulting, Surrey, United Kingdom 1340- 1410h

8. Integrated Assessment Methods for Better Failure Analysis an important Approach to

Enhance Reliability of Equipment for longer Life at Industrial Plants
Dr Abdulaziz Almathami, R&D Group Manager, Corrosion & Material Group, Baker Hughes,
Dhahran Global Technology Center, Dhahran Saudi Arabia 1410- 1440h

Tea Break 1440 1510h

Keynote Paper
9. Operational Governance to Sustain Operational Excellence (BAPCO Case Study)
Ms. Sumah Hammad, Operational Excellence Management System Leader, Bahrain Petroleum
Company (BAPCO), Manama, Bahrain 1510- 1550h

Closing Ceremony and Networking 1550 1630h

 2-Day Training Course aimed at Industry

P/T 91/ P92 Fabrication, welding, Heat

Treatment, Oxidation, Damage
Mechanisms & Integrity/life assessment

Recently there has been a concern in high temperature industry following a number of failures in P91 thick section
components (at plant operating life of as short as 20,000 hours) and in dissimilar metal welds (at plant life of only 5,000
hours or so). In the case of T91 thin section components recent findings from research and demonstration projects
(supported by limited plant experience) have shown the steam side performance of this steel not as good as originally
predicted with reports of replacement by some utilities of T91 superheater tubing after only a short service duration.
Furthermore, recent work and publications by plant manufacturers, operators and researchers have shown that, unlike
the traditional CrMoV steels, the heat treatment of P91 and P92 steels both during and after component and weld
production needs to be precise as its control and management can be critical in determining the integrity of P91 and P92
components. Successful plant operators have relied on detailed P91/P92 material understanding and component quality
checks to ensure safe and reliable operation of their plant. Similarly for welding the more successful plant manufacturers
have relied on high quality welding and have followed more promising procedures. However, unfortunately there is no
international consensus on the best procedures to use. Some international procedures/ recommended practices have
now been found not to be suitable for this steel but will continue to be followed for various reasons. Partly as a result of
this, there is new steel in the market, and old one in service that needs more careful analysis, NDE, hardness checks,
component monitoring and integrity assessment.

Moreover, in the new competitive market outsourcing has become a common practice by the manufacturers in an effort
to cut the price of new plant. But sometimes outsourcing of plant manufacturing and welding to companies and countries
with relatively less experience and unsatisfactory practices has caused, and continues to cause, problems with new plants
using this material. In the case of HRSGs this can have even more far reaching effects due to their compact nature and
thus the difficulty of access to many components for monitoring or repair. Thus the plant manufacturers, owners,
operators, service providers and inspection/ insurance/ safety authorities all need to be aware of the complexities of the
issues involved and how to recognize problems when they occur in components made from this steel e.g. vulnerable
casts, incorrect heat treatment etc. both at the purchase and at the plant operation stages.

The understanding of the basic mechanisms and characteristics of these steels will enable the plant operators and service
providers to help operate plant more efficiently and reduce forced outage periods and associated costs/ risks. It will help
them to better develop component monitoring strategies, take palliative measures in time and make informed run/ repair/
replacement decisions.

At the plant component mid-life stage, when a few of the P91 components have already shown problems/ cracking/
failures, a basic understanding of the underlying principles of this material behavior will help to develop cost effective
procedures for damage assessment and life prediction and an understanding of how life of older plant/ structures can
be extended
 T R A I N I N G DAY ONE
Tuesday, 18 October 2016
08:30 Registration and Coffee
09:00 Welcoming by AMCO Team

DAY - 1
Understanding Material Properties, Microstructure, Heat
Treatment and Steam Side Oxidation of Thin Wall Tubing

Session 1: Material Properties and Heat Treatment

0900 1300 h (with 30 minutes break)

Dr David Robertson
Lead Metallurgist
ETD Consulting, UK

Objective

To develop a better understanding of the underlying concepts and basis of P91 development,
its properties, the effect of heat treatment, chemical composition and understanding its weldment
behaviour.

Specific topics will include:

P91/ P92 specifications, inspections and control required during manufacturing and erection
processes.
Availability of material from various sources and quality control and checks required when
purchasing and receiving material. Acceptance test of components, hardness, microstructure
etc.
The effect of heat treatment (autenitising/normalising and tempering) on microstructure and
hardness and best available practices.
The effect of heat treatment on material strength, creep strength, hardness and ductility etc.
The effect of chemical composition details and what to look for.
European, ASME and other codes, practices, recommendations, standards and their
differences.
Potential sources of materials data.

Lunch Break 1300 1400h

Session 2: Steam-Side Oxidation of Thin Wall Tubing, Failure, Repair and Replacement
1400 1700 hrs (with 30 minutes break)

Prof Dr Fujimitsu Masuyama,

Dept. of Materials Science and
Engineering,
Kyushu Institute of Technology,
Japan

Objective

To create a better understanding of the basic principles of oxidation in steam and its effect on
tube over-heating and cracking/ failure.

Specific topics will include:

Basic principles of T91/ T92 oxidation, research.
T91 tubing demonstration and plant failure experience due to steam side oxidation.
The effect of steam side oxidation on tube metal temperature for T91/ T92 tubing and its
consequences.
Effect of plant cycling on oxide spallation.
Comparison of behaviour with traditional low alloy CrMoV steels.
Damage effect of T91 spalled oxide on other plant components.
Repair and replacement of failed tubes and issues involved.

Professor Masuyama has been teaching and conducting research in

Kyushu Institute of Technology, Japan, in Mechanical
Metallurgy and Product System Engineering since April 2003, retiring from
Mitsubishi Heavy Industries.

He has about 40-year experience in materials science, mechanical/ physical metallurgy,

corrosion science, joining, and boiler and pressure vessel technology. His experience and
expertise traverse both materials technology and fabrication technology for non-nuclear and
nuclear heat exchanger and pressure vessel. Prof Masuyama is the inventor of Grades 23,
122, HCM9M, and HCM12, and has been instrumental in the commercial application of Grades
91 and 92 in the ultra-super critical power plants.

T R A I N I N G DAY T W O
Education: Fujimitsu Masuyama received PhD from Osaka University, Japan.
 Wednesday, 19 October 2016
08:30 Registration and Coffee
09:00 Welcoming by AMCO Team

Day - 2
Understanding Material Welding, Welded Component Behaviour and
Component Integrity / Life Assessment Issues

Session 3: P91/ P92 Component Integrity/Life Assessment

0900 1300 h (with 30 minutes break)

Prof Dr Fujimitsu Masuyama,

Dept. of Materials Science and
Engineering,
Kyushu Institute of Technology,
Japan

Objectives

To understand how P91/ P92 component integrity can be assessed. What are the available
techniques and the advantages that they may offer. This includes a better understanding of the
basic principles of oxidation in steam and its effect on tube over-heating and cracking/ failure.

Specific topics will include:

Late cavitation development due to creep.

Ductility and hardness issue.
Type IV failures and their early detection.
NDE techniques and their use for life assessment.
Potential of the use of new NDE type techniques.
Developments in Europe and Japan for life assessment of P91/ P92 component integrity /
life assessment.
Session 4: Welding and Welded Component Behaviour
1400 1700 hrs (with 30 minutes break)

Dr David Robertson
Lead Metallurgist
ETD Consulting, UK

Objective
To create an understanding of the welding and pre- and post-weld heat treatment requirements
and the criticality of the precise control required for this steel. These issues will refer to industrial
experience to date.
Specific topics will include:

Suitable welding procedures
Pre-and post-weld heat treatment and Type IV failures in thick section components.
Strength/ life reduction factors.
Effect of plant cycling on cracking type, especially Type IV cracking.
Weld repair issues.
Dissimilar metal weld issues (P91/ P92 to low CrMoV steel welding, P91/ P92 to austenitic
stainless steel welding), the effect of cycling and lessons from plant experience.

Certificate Distribution and Course Review

Dr Robertson gained his qualifications in metallurgy and materials

at Imperial College, London. He has over twenty years experience of
Materials used in the power, petrochemical and other industries. Since
2004, Dr Robertson has been working for ETD Consulting on Projects
related to high-temperature plant integrity and life assessment, materials and welding issues,
and root cause failure analysis.
Through his work, Dr Robertson has gained extensive experience of the materials used and
damage/failure mechanisms in high-temperature plants. He also has considerable experience
in examination and interpretation of metallographic replicas in order to assess metallurgical
damage and degradation (creep cavitation, spherodization, etc).

Dr Robertson has been coordinating the Group since it was formed by ETD in 2006 to better
inform international industry about the issues related to use of grade 91 steel.

Dr Robertson regularly lectures on materials, component damage, maintenance issues and life
assessment as part of ETDs training courses on Life Assessment of High Temperature Plant,
HRSG Integrity, Boiler Maintenance and new materials (P91/P92, etc). Courses have been
held in the UK, Europe, Canada, Malaysia, Middle East, Philippines and USA.
 REGISTRATION Team Discounts
You can register yourself or your colleague via sending this form to Team Discounts are available, please
contact sales@amco-consult.com
sales@amco-consult.com

CONFERENCE PRICES Venue & Accommodation

BOOK AND PAY BEFORE 25th September 2016 AND SAVE UP TO SAR 2000
Early Bird Price:
Payment before 25th Standard Price: Benefits
A u g u s t 2016

ALL-ACCESS SAR 6,000 Attend all the event (Conference +

SAR 8,000
Conference + 2 D a y s T r a i n i n g (Save SAR 2000) Training)
SAR 5,000
Networking opportunity
Conference Only SAR 6,000 Conference Papers + Presentations
(Save SAR 1000)
Access to Group Discussion notes
SAR 5,000
T ra i n i n g Only (Save SAR 1000)
SAR 6,000 Access to Training Notes

SPONSORSHIPS DETAILS Benefits of Sponsorship

Exhibition Stand Space
Platinum SAR 50,000 Attend all 4 days of the conference
+ Training
Gold SAR 35,000 Company names, logo & profile on
Silver SAR 25,000 all the conference Materials
Roll up display
DELEGATE DETAILS Free advertisement
Networking opportunity
Mr. Ms. Dr. Engr. Prof. Other.

First Name: ... Surname ........................................ Note: Details of the sponsorship can be
shared in separate email.
Email:Telephone:

Job Title: .. Department: HOTEL DETAILS

Company: Address: ..

City: . Country: .
Intercontinental Hotel
Signature: Date: .

P.O. Box 10167

Al Jubail Al Sinaiyah 31961
Kingdom of Saudi Arabia
Tel: +966 13 356 4000