COURSE OVERVIEW:

The systematic inspection planning for static equipment such as columns, drums, reactors, and heat exchangers is fundamental to ensuring the operational integrity and safety of downstream processing facilities. This course focuses on the transition from traditional time-based inspection intervals to sophisticated risk-based strategies that prioritize equipment based on potential failure modes and their associated consequences. Participants will learn how to synthesize design data, process parameters, and historical maintenance records to create a robust inspection framework that minimizes downtime while maximizing asset reliability and safety performance.

The scope of this training involves a detailed examination of the unique internal and external components of pressure vessels and heat transfer equipment. For columns and drums, the focus is on internals such as trays, packing, and mist eliminators, while for reactors, the curriculum addresses the complexities of catalyst support systems and high-temperature metallurgy. The course also provides extensive coverage of heat exchanger bundle inspections, including tube-side and shell-side degradation mechanisms. By understanding the specific operational stresses placed on these diverse assets, participants will be able to select the most effective non-destructive testing techniques for each application.

Detailed Coverage includes the application of API 510, API 580, and API 581 standards as they relate to the planning and execution of internal and external inspections. The course explores the development of Detailed Inspection Plans (DIP), the evaluation of damage mechanisms such as high-temperature hydrogen attack (HTHA), stress corrosion cracking, and thermal fatigue. Through a combination of technical theory and practical planning exercises, attendees will gain the skills necessary to optimize turnaround schedules and ensure that every inspection activity provides high-value data for fitness-for-service assessments and long-term asset management.

COURSE OBJECTIVES:

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

• Define the technical requirements for inspecting static pressure equipment according to API and ASME standards.
• Categorize specific damage mechanisms for columns, drums, reactors, and heat exchangers based on process conditions.
• Develop a Risk-Based Inspection (RBI) plan that aligns with facility-specific reliability targets and safety goals.
• Evaluate the effectiveness of various NDT methods for detecting localized corrosion and environmental cracking.
• Interpret inspection findings to determine the remaining life and next inspection interval for pressure vessels.
• Design comprehensive inspection scopes for planned turnarounds to ensure all critical components are assessed.
• Analyze the impact of process changes and feedstock variations on the degradation rates of static equipment.
• Implement strategies for the inspection of reactor internals and specialized catalyst containment systems.
• Assess the integrity of heat exchanger tubes using advanced electromagnetic and ultrasonic techniques.
• Coordinate the documentation of inspection results to support regulatory compliance and engineering audits.
• Recommend appropriate repair or mitigation actions based on the severity of identified defects.
• Facilitate multidisciplinary meetings to integrate inspection data with maintenance and production planning.

TARGET AUDIENCE:

This course is intended for Inspection Engineers, Pressure Vessel Engineers, Reliability Professionals, Plant Inspectors, and Turnaround Planners. It is also highly relevant for Maintenance Managers, Process Engineers, and Quality Assurance Specialists who are responsible for the life cycle management of static equipment in refineries, petrochemical plants, and heavy industrial facilities.

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:

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