Course Overview
Course Description
This intensive 10-day course provides comprehensive training on the inspection, evaluation, and repair of process plant equipment and connected piping. Participants will gain in-depth knowledge of industry standards, best practices, and cutting-edge techniques for maintaining plant integrity and reliability. The course covers a wide range of topics, from basic inspection methods to advanced repair strategies, equipping attendees with the skills needed to enhance plant safety and efficiency.
Learning Objectives
- Understand and apply industry codes and standards for equipment inspection and repair
- Master various inspection techniques and their appropriate applications
- Develop skills in evaluating equipment condition and determining fitness-for-service
- Learn effective repair and alteration methods for process plant equipment and piping
- Gain proficiency in risk-based inspection and maintenance planning
- Enhance decision-making skills for equipment lifecycle management
Course Modules
Day 1: Introduction to Process Plant Equipment Integrity
- Overview of process plant equipment and piping systems
- Importance of equipment integrity in plant safety and reliability
- Introduction to industry codes and standards (ASME, API)
- Basic principles of equipment lifecycle management
Day 2: Inspection Techniques and Tools
- Visual inspection methods and best practices
- Non-destructive testing (NDT) techniques
- Advanced inspection technologies (e.g., drones, robotics)
- Inspection data collection and management
Day 3: Corrosion and Degradation Mechanisms
- Common corrosion types in process plants
- Material degradation mechanisms
- Corrosion monitoring techniques
- Corrosion prevention and control strategies
Day 4: Risk-Based Inspection (RBI)
- Principles of risk-based inspection
- RBI methodologies and implementation
- Developing and managing an RBI program
- Case studies in RBI application
Day 5: Fitness-for-Service (FFS) Assessment
- Introduction to FFS concepts and methodologies
- API 579/ASME FFS-1 standards overview
- FFS assessment techniques for common damage mechanisms
- Practical examples and case studies
Day 6: Piping Inspection and Evaluation
- Piping system components and failure modes
- Inspection techniques for piping systems
- Evaluation of piping condition and remaining life
- Piping flexibility analysis and stress assessment
Day 7: Pressure Vessels and Storage Tanks
- Inspection and evaluation of pressure vessels
- Storage tank inspection techniques
- Fitness-for-service assessment for vessels and tanks
- Repair and alteration considerations
Day 8: Rotating Equipment Inspection
- Inspection techniques for pumps, compressors, and turbines
- Vibration analysis and monitoring
- Lubrication system inspection and maintenance
- Alignment and balancing considerations
Day 9: Repair and Alteration Techniques
- Welding repair methods and considerations
- Mechanical repair techniques
- Composite repairs for piping and equipment
- Quality control in repair and alteration projects
Day 10: Maintenance Planning and Management
- Developing effective maintenance strategies
- Shutdown planning and execution
- Root cause analysis of equipment failures
- Continuous improvement in maintenance practices
Practical Wins for Participants
- Ability to develop and implement risk-based inspection programs
- Skills to perform fitness-for-service assessments on damaged equipment
- Knowledge to make informed decisions on equipment repair vs. replacement
- Capability to enhance plant reliability and reduce unplanned downtime
Have Questions About This Course?
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