COURSE OVERVIEW:

The meaning of piping process mechanical integrity refers to the lifecycle management of piping systems to ensure they perform their intended function without failure, particularly in hazardous or high-pressure services. This course bridges the gap between the original construction requirements of ASME B31.3 (Process Piping) and the post-construction inspection and maintenance rules of API 570. By understanding how design assumptions influence long-term degradation, participants can develop a robust integrity program that balances operational availability with safety.

The scope of the training covers the technical requirements for materials, design, fabrication, and testing of new piping systems, as well as the specialized procedures for inspecting and re-rating piping that is already in service. Participants will explore the physics of piping failure, including creep, fatigue, and various corrosion mechanisms. The course emphasizes the importance of the "Authorized Piping Inspector" and the engineering calculations required to determine if a thinning pipe can safely remain in operation or requires immediate remediation.

The coverage of the program is organized into twelve modules, starting with the fundamental design codes and moving into the practicalities of field inspection. Key topics include the calculation of minimum wall thickness, the evaluation of piping supports, the management of "Injection Points," and the implementation of Risk-Based Inspection (RBI). The program concludes with a focus on documentation and the integration of inspection results into a plant-wide Mechanical Integrity (MI) program to satisfy regulatory requirements such as OSHA PSM.

COURSE OBJECTIVES:

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

• Distinguish between the jurisdiction of ASME B31.3 (Construction) and API 570 (In-Service).
• Calculate the minimum required wall thickness and MAWP for process piping.
• Identify and categorize common piping damage mechanisms according to API 571.
• Execute a comprehensive piping inspection plan involving CMLs and TMLs.
• Evaluate the impact of piping thermal expansion and support failure on integrity.
• Understand the requirements for qualifying welding procedures and welders.
• Determine the remaining life and next inspection date for degraded piping.
• Perform screening for "Corrosion Under Insulation" (CUI) and "Dead Legs."
• Apply the principles of Fitness-for-Service (FFS) to piping anomalies.
• Oversee the quality of piping repairs and alterations in a plant environment.
• Classify piping systems (Class 1, 2, 3, 4) to set appropriate inspection frequencies.
• Manage the documentation required for a legally defensible Mechanical Integrity program.

TARGET AUDIENCE:

This course is intended for Piping Engineers, Plant Inspectors, Maintenance Managers, Reliability Technicians, and QA/QC Professionals involved in refinery, petrochemical, and chemical plant operations.

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.