Process Plant Equipment Inspection & Repair Techniques Event, 03.Nov.2025

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