COURSE OVERVIEW:

The development of a robust inspection program for refineries and process plants serves as the primary defense against catastrophic equipment failure and unplanned shutdowns. This course explores the integration of international codes and standards to establish a systematic approach for monitoring the mechanical integrity of static equipment. By focusing on the structural health of pressure vessels, piping, and storage tanks, participants learn to balance operational efficiency with the stringent safety requirements of the modern hydrocarbon processing industry.

The scope of this training encompasses the entire lifecycle of inspection planning, from the initial identification of damage mechanisms to the final documentation of remedial actions. It delves into the technical application of API and ASME standards, providing a framework for creating inspection schedules that are both cost-effective and compliant with global regulations. Participants will examine how to translate complex engineering data into actionable inspection tasks, ensuring that every piece of critical infrastructure is accounted for within a comprehensive maintenance strategy.

Coverage includes detailed analysis of Risk-Based Inspection (RBI) methodologies, Non-Destructive Testing (NDT) selection, and the interpretation of corrosion data within process environments. The curriculum addresses the nuances of high-temperature and high-pressure operations, teaching attendees how to identify vulnerable points within a facility. By the end of the program, participants will possess the expertise to design, implement, and manage a code-driven inspection department that prioritizes risk mitigation and long-term asset reliability.

COURSE OBJECTIVES:

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

1.  Develop a comprehensive inspection philosophy based on API 510, API 570, and API 653 standards.

2.  Identify and categorize various damage mechanisms specific to refinery process units.

3.  Utilize Risk-Based Inspection (RBI) principles to prioritize equipment based on the probability and consequence of failure.

4.  Establish precise inspection intervals and frequencies for pressure vessels and piping systems.

5.  Select the most effective Non-Destructive Testing (NDT) methods for detecting localized corrosion and cracking.

6.  Interpret ASME Section VIII and B31.3 requirements for post-repair inspection and pressure testing.

7.  Design a systematic data management process for recording and analyzing inspection findings.

8.  Evaluate the remaining life of equipment through advanced thickness measurement and monitoring techniques.

9.  Implement a quality assurance and quality control (QA/QC) framework for third-party inspection services.

10.  Formulate detailed inspection reports that facilitate informed decision-making for plant management.

11.  Apply Fitness-for-Service (FFS) assessments according to API 579 to determine continued equipment viability.

12.  Coordinate between operations, maintenance, and inspection teams to minimize turnaround durations.

TARGET AUDIENCE:

This course is designed for Inspection Engineers, Mechanical Engineers, Reliability Engineers, Plant Integrity Managers, Quality Assurance Personnel, and Refinery Operations Supervisors who are responsible for the safety and reliability of process plant equipment.

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.