The longevity and safety of a process plant depend heavily on the reliability of its static assets, such as pressure vessels, heat exchangers, and piping systems. This course addresses the technical and managerial strategies required to improve the reliability and integrity of static equipment throughout its operational life. By shifting from a purely reactive mindset to a proactive reliability-centered approach, organizations can minimize the risk of containment loss and extend the intervals between major shutdowns.

The scope of this training encompasses the modern tools used for asset health monitoring and the identification of systemic causes for equipment degradation. Participants will explore the principles of Mechanical Integrity (MI) programs and how to integrate reliability data into the decision-making process. We will examine the critical role of material selection, design optimization, and effective maintenance practices in preventing premature failure and ensuring predictable performance.

Coverage includes the analysis of "Bad Actors," the implementation of Fitness-for-Service assessments, and the utilization of advanced NDT for targeted inspections. The curriculum focuses on building a culture of reliability where every stage—from design to decommissioning—is scrutinized for potential integrity improvements. By completing this course, delegates will be equipped to develop and lead initiatives that significantly reduce the total cost of ownership for static equipment.

COURSE OBJECTIVES:

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

• Define the core elements of a Mechanical Integrity (MI) program.
• Analyze equipment failure data to identify trends and "Bad Actor" assets.
• Implement proactive reliability strategies for heat exchangers and vessels.
• Utilize Root Cause Analysis (RCA) to prevent the recurrence of static equipment failures.
• Evaluate the impact of process conditions on the long-term integrity of assets.
• Apply Fitness-for-Service (FFS) principles to justify continued operation of flawed equipment.
• Optimize maintenance and inspection programs to improve equipment uptime.
• Identify opportunities for metallurgical upgrades to mitigate recurring corrosion issues.
• Develop reliability-centered maintenance (RCM) plans for static components.
• Supervise the quality of repairs and modifications to ensure structural integrity.
• Integrate condition monitoring data into the overall asset management strategy.
• Communicate the value of reliability improvements in terms of safety and ROI.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Static Equipment Engineers, Maintenance Managers, Integrity Specialists, and Plant Operation Leads.

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.