COURSE OVERVIEW:

The integrity of piping systems is often compromised not by the primary process lines themselves, but by the failure of secondary components such as piping supports and small-bore connections. These elements are frequently overlooked during routine inspections, yet they represent a significant percentage of loss-of-containment incidents in refineries and chemical plants. This course provides a technical deep dive into the mechanical behavior, stress distribution, and degradation patterns of supports and small-diameter piping, ensuring that participants can identify latent threats before they escalate into catastrophic failures.

The scope of this training involves the comprehensive study of piping restraint systems, including spring hangers, rigid supports, and snubbers, alongside the unique vulnerabilities of small-bore connections (typically 2 inches and below). Participants will examine the physics of vibration-induced fatigue, which is the leading cause of failure in cantilevered small-bore branches. The coverage extends to the interaction between the piping system and its structural environment, focusing on how thermal expansion and improper support settings can lead to localized overstressing and eventual rupture of the pressure boundary.

Participants will be guided through the development of robust inspection protocols that utilize both visual and advanced non-destructive testing methods. The course emphasizes the importance of "dead-leg" management and the specific challenges of corrosion under insulation (CUI) as they relate to support interfaces and small-diameter junctions. By the end of the program, attendees will have a clear framework for auditing their existing piping systems and implementing a risk-based approach to the maintenance of these critical, yet often neglected, mechanical assets.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Identify the various types of piping supports and their specific roles in maintaining system equilibrium.
• Detect early signs of fatigue in small-bore connections caused by high-frequency vibration or acoustic-induced vibration.
• Evaluate the condition of spring supports and determine if they are operating within their design travel range.
• Assess the integrity of small-bore branch connections and the effectiveness of bracing systems.
• Recognize the symptoms of piping stress caused by restricted thermal expansion due to frozen or improperly installed supports.
• Implement effective inspection techniques for identifying corrosion at support touchpoints and under pipe clamps.
• Analyze the risks associated with "dead-legs" and stagnant small-bore lines in corrosive services.
• Apply international codes and standards such as ASME B31.3 and MSS SP-58 to inspection criteria.
• Distinguish between acceptable and unacceptable levels of pipe sagging and misalignment.
• Develop a prioritized inspection schedule for small-bore connections based on process criticality and vibration levels.
• Recommend appropriate repair and reinforcement strategies for weakened supports and vibrating branches.
• Document inspection findings with technical precision to support long-term asset integrity management.

TARGET AUDIENCE:

This technical course is specifically designed for Mechanical Inspectors, Piping Engineers, Asset Integrity Engineers, Maintenance Technicians, and Reliability Engineers working in the oil, gas, petrochemical, and power generation sectors. It is also highly relevant for Quality Assurance and Quality Control (QA/QC) personnel and Plant Managers who are responsible for reducing unplanned downtime and improving the safety performance of pressurized piping systems.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

The National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants who complete a minimum of 80% of the total attendance time requirement.