Plant Integrity Management

Suitable for:

The course is aimed at plant engineers, non-destructive testing engineers, materials and corrosion engineers, plant inspectors responsible for managing the integrity of ageing process equipment, pipelines, boilers and storage tanks.

It is recommended that attendees have a knowledge of either the inspection, design, fabrication, operation or maintenance of process equipment and piping, as well as some knowledge of the most common pressure equipment design codes/standards.

Course Content:

RISK-BASED INSPECTION (RBI) BASED ON API RP 580 AND 581 AND ASME
RBI in accordance with API BRD 581, API RP 580 and ASME; reasons for implementing RBI; benefits of using RBI; practical implementation of RBI; planning successful RBI implementation projects; practical likelihood and consequence analysis; preparing inspection plans and optimising maintenance and inspection intervals; implementing risk mitigation actions; overview of other procedures (e.g. RIMAP, ASME, etc) and related API documents (API 510, API 570 and API 653).

FITNESS-FOR-SERVICE (FFS) ASSESSMENT BASED ON API 579-1/ASME FFS-1 2007
This course has been developed, based around the new API/ASME combined standard (API 579 Second Edition) which has been expanded to address material damage mechanisms other than just those commonly found in refining industry equipment.

Introduction to FFS; material properties and the API 579 Annexes; stress analysis for FFS; non-destructive testing and flaw sizing for FFS; identification of damage mechanisms for FFS; brittle fracture; general metal loss; localised metal loss; pitting; laminations; weld misalignment and shell distortion; crack-like flaws; creep; fire damage; hydrogen blisters; hydrogen damage associated with HIC and SOHIC; dents and gouges; remaining life assessment and life extension examples; repair and remediation options; status of API 579 and future developments; interaction with other assessment procedures (e.g. FITNET, BS 7910, R5 and R6) and related API documents (API 510, API 570 and API 653)

DAMAGE MECHANISM ASSESSMENT FOR RBI AND FFS BASED ON API RP 571
Common damage mechanisms in all major oil and gas production, refining and manufacturing processes and where they can be found; key process parameters affecting these damage mechanisms; prevention and control of these damage mechanisms; the most appropriate inspection and non-destructive testing methods for these damage mechanisms.

REPAIR OF PRESSURE EQUIPMENT AND PIPING WORKSHOP
Design for repair, repair-no repair decision, Engineering Critical Assessments (ECA)/Fitness-For-Service (FFS) assessments, repair codes and standards (such as API 510, API 570, API RP 2200, API 573), methods of repair-cold versus hot repair, production control, method statements for repair, qualifications for repair, inspection - pre and post repair. The workshop will include presentation by insurers and certification agencies on their position with respect to repair. Case studies will be presented - where repairs have gone wrong and the development of successful welding repair methodologies.

REPAIR OF PRESSURE EQUIPMENT AND PIPING TRAINING
Introduction to weld repairs, differentiation in requirements between production and in-service-repairs, considerations for weld repair (including decision tree), qualification requirements, industry best practices, techniques for weld repair such as temper bead/controlled deposition repair, novel repair technologies such as taper stitch welding, repair methodologies for different types of failure mechanisms such as creep, SSCC, corrosion damage and clad repair.

Objectives:

RISK-BASED INSPECTION (RBI) BASED ON API RP 580 AND 581 AND ASME
At the end of the course, attendees will be able to:

• Confidently explain the differences between Level 1, Level 2 and Level 3 RBI assessments
• Understand the reasons for and benefits of implementing RBI
• Undertake rapid practical RBI implementation
• Plan successful RBI projects
• Prepare risk-based inspection plans and optimise maintenance and inspection intervals
• Recommend suitable risk mitigation actions

FITNESS-FOR-SERVICE (FFS) ASSESSMENT BASED ON API 579-1/ASME FFS-1 2007
At the end of the course, attendees will be able to:

• Confidently apply the latest FFS technologies for making repair, replace, re-rate and re-design decisions
• Understand the information requirements for performing FFS assessments for brittle fracture, general metal loss, localised metal loss, pitting, laminations, weld misalignment and shell distortion, crack-like flaws, creep; fire damage; hydrogen blisters; hydrogen damage associated with HIC/SOHIC; dents and gouges
• Use FFS on process equipment, pipelines, boilers and storage tanks

DAMAGE MECHANISM ASSESSMENT FOR RBI AND FFS BASED ON API RP 571
At the end of the course, attendees will be able to:

• Confidently identify common damage mechanisms in major oil and gas production, refining and petrochemical processes and where they may be found
• Understand the key factors affecting these damage mechanisms and the prevention and control of these damage mechanisms
• Recommend the most appropriate inspection and non-destructive testing methods for these damage mechanisms

REPAIR OF PRESSURE EQUIPMENT AND PIPING - WORKSHOP AND TRAINING
At the end of the workshop and training course, attendees will be able to:

• understand the considerations to be applied before carrying out weld repairs;
• prepare method statements and carry out qualifications;
• apply industry best practice for weld repair.