COURSE OVERVIEW:

The meaning of piping repairs, alterations, and re-rating according to API 570 encompasses the engineering and operational activities required to maintain or modify existing piping systems while adhering to safety codes. This course provides a technical roadmap for managing changes to pressurized piping, whether through physical repairs of degraded sections, the implementation of alterations to process flow, or the analytical re-rating of a system's pressure and temperature limits. By following the API 570 framework, participants can ensure that all modifications are performed with the same level of integrity as the original construction.

The scope of the training includes the detailed study of repair methodologies for both temporary and permanent fixes, including the use of fillet-welded patches, full-encirclement sleeves, and flush-patch repairs. Participants will explore the strict requirements for qualifying welding procedures and personnel, especially for in-service welding on live lines. The course also provides the mathematical basis for re-rating piping systems, allowing engineers to safely increase or decrease operational parameters based on current thickness data and material properties.

The coverage of the program is structured across ten modules that emphasize the synergy between the inspector, the engineer, and the repair contractor. Key topics include the definition of "alterations" versus "repairs," the requirements for pressure testing after a modification, and the use of non-destructive testing (NDT) to validate the quality of the work. The course also addresses the practicalities of hot tapping and the management of "seal-welded" joints. The program concludes with a focus on documentation, ensuring that every repair or re-rating is backed by a technical file that satisfies jurisdictional authorities.

COURSE OBJECTIVES:

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

• Distinguish between a "Repair" and an "Alteration" as defined by API 570.
• Select appropriate repair methods for metal loss, cracks, and pitting.
• Design permanent steel repairs using the ASME PCC-2 standard.
• Execute the requirements for "In-Service" welding and hot tapping.
• Calculate the new pressure and temperature limits for a Piping Re-rating.
• Identify the conditions where a "Fitness-for-Service" assessment is required.
• Approve Welding Procedure Specifications (WPS) for piping repairs.
• Determine when a pressure test (Hydrostatic or Pneumatic) is mandatory.
• Apply NDT techniques to verify the integrity of completed repairs.
• Manage the documentation process for piping alterations and re-ratings.
• Evaluate the use of non-metallic (composite) repairs for piping.
• Ensure compliance with ASME B31.3 and API 570 for all modifications.

TARGET AUDIENCE:

This course is intended for Authorized Piping Inspectors (API 570), Plant Engineers, Maintenance Managers, Welding Engineers, and Quality Assurance Specialists.

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.