COURSE OVERVIEW:

The core of asset integrity management lies in the ability to make high-stakes engineering decisions when equipment is found to be damaged or degraded. This course provides a rigorous technical framework for choosing the optimal path between repairing a component, replacing it entirely, re-rating its operational parameters, or continuing to run as-is with enhanced monitoring. Participants will explore the engineering basis for these decisions, balancing the immediate needs of production with the long-term requirements of safety, regulatory compliance, and structural reliability. The program focuses on removing subjectivity from the decision-making process by utilizing quantitative data and international engineering codes.

The scope of this training involves the application of advanced Fitness-for-Service (FFS) principles and risk-based logic to various industrial scenarios. Participants will learn how to evaluate the "Cost of Quality" and the technical feasibility of different intervention strategies. The curriculum covers the analysis of metal loss, cracking, and geometric distortions, teaching attendees how to determine if a defect is stable or if it poses an immediate threat to the pressure boundary. By understanding the mechanical limits of materials and the effectiveness of different repair technologies, participants will be equipped to provide management with clear, justified, and safe recommendations.

Detailed coverage is provided on the legal and insurance implications of "Run-or-Repair" decisions. The course explores the administrative requirements for re-rating equipment to lower pressures or temperatures and the technical requirements for validating "temporary" repairs as permanent solutions. Through complex case studies involving piping, vessels, and tanks, attendees will develop the critical thinking skills necessary to navigate the trade-offs between capital expenditure and operational risk. The program emphasizes that every integrity decision must be backed by an auditable engineering record that withstands the scrutiny of both internal audits and external regulatory inspections.

COURSE OBJECTIVES:

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

• Apply a structured engineering methodology to choose between repair, replacement, re-rating, or running.
• Conduct Level 1 and Level 2 Fitness-for-Service assessments according to API 579-1/ASME FFS-1.
• Evaluate the technical and economic life cycle costs associated with each decision path.
• Determine the "Point of Diminishing Returns" where repair costs outweigh replacement value.
• Define the technical requirements for re-rating pressure equipment for new process conditions.
• Analyze the risks of "Run-to-Failure" strategies versus proactive intervention.
• Select appropriate repair techniques based on ASME PCC-2 and assess their long-term reliability.
• Justify "Run-as-Is" decisions for stable defects using fracture mechanics and crack growth modeling.
• Document the engineering basis for integrity decisions to satisfy regulatory and insurance audits.
• Coordinate multi-disciplinary reviews involving process, materials, and maintenance engineering.
• Assess the impact of operational changes on the validity of previous integrity decisions.
• Communicate complex technical recommendations to non-technical stakeholders with clarity.

TARGET AUDIENCE:

This course is designed for Senior Inspection Engineers, Asset Integrity Managers, Plant Engineers, Reliability Specialists, and Maintenance Managers. It is also highly beneficial for Technical Directors, Project Managers, and Finance Professionals in the energy and process sectors who are involved in the approval of large-scale maintenance expenditures and capital replacement projects.

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.