COURSE OVERVIEW:

Integrity assessment of aging assets and life extension planning is a critical discipline for industrial operators seeking to maximize the return on investment of existing infrastructure while maintaining uncompromising safety standards. As global industrial plants exceed their original design lives, the challenge shifts from routine maintenance to complex engineering evaluations that determine the feasibility of continued operation. This course provides a structured methodology for identifying the cumulative effects of time-dependent degradation, such as creep, fatigue, and corrosion, and assesses how these factors impact the structural reliability of static and rotating equipment.

The scope of this program covers the multi-disciplinary approach required to move beyond nominal design limits through rigorous technical validation. Participants will explore the "Life Extension Framework," which involves data mining of historical records, advanced physical testing, and probabilistic modeling. The curriculum emphasizes the distinction between the "Design Life" and the "Technical Life" of an asset, providing the tools necessary to bridge this gap through targeted interventions. Coverage includes the evaluation of safety margins, the impact of cyclic loading on older metallurgy, and the re-validation of equipment for current and future operational envelopes.

Detailed instruction is provided on the application of international codes such as API 579-1/ASME FFS-1 and ISO 2394 in the context of aging infrastructure. The course explores the economic and technical trade-offs of repair versus replacement, the role of structural health monitoring in extending service intervals, and the regulatory requirements for documenting life extension. By analyzing case studies of successful longevity programs in refineries, offshore platforms, and power plants, attendees will learn how to develop a "Life Extension Safety Case" that satisfies both internal corporate risk tolerances and external regulatory mandates.

COURSE OBJECTIVES:

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

• Define the core concepts of aging management and the technical basis for life extension.
• Identify time-dependent degradation mechanisms that specifically target older industrial assets.
• Conduct a comprehensive gap analysis between original design codes and current industry standards.
• Perform Fitness-for-Service assessments to Level 2 and Level 3 for aging pressure equipment.
• Evaluate the cumulative fatigue damage and remaining creep life of high-temperature components.
• Implement structural health monitoring (SHM) systems to provide real-time data on aging assets.
• Utilize probabilistic methods to determine the Remaining Useful Life (RUL) of critical systems.
• Assess the integrity of "non-inspectable" areas using advanced indirect inspection techniques.
• Develop a Life Extension Management Plan (LEMP) including necessary hardware upgrades.
• Justify the continued operation of assets to regulatory bodies using quantitative risk data.
• Determine the economic tipping point where replacement becomes more viable than maintenance.
• Coordinate multi-disciplinary teams for the execution of major life extension projects.

TARGET AUDIENCE:

This course is specifically designed for Asset Integrity Managers, Plant Engineers, Reliability Specialists, Structural Engineers, and Maintenance Managers. It is also highly relevant for Technical Directors, Regulatory Compliance Officers, and Investment Analysts who are involved in the strategic decision-making process regarding the longevity and safety of aging industrial infrastructure.

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.