COURSE OVERVIEW:

The meaning of mechanical integrity and energy efficiency for static equipment refers to the specialized management of non-rotating assets—such as boilers, heat exchangers, pressure vessels, and piping—to ensure they are leak-free, structurally sound, and thermally efficient. This course focuses on the principle that mechanical degradation in static assets, such as fouling in exchangers or insulation failure in piping, directly leads to massive thermal losses and process inefficiencies. By implementing "Risk-Based Inspection" (RBI) and advanced thermal management, organizations can ensure that their core process equipment operates at peak thermodynamic efficiency.

The scope of this training encompasses the analysis of heat transfer degradation, pressure drop management, and the science of "Thermal Insulation" systems. It examines the technicalities of corrosion and fouling mechanisms—such as scaling in boilers and oxidation in reactors—which act as thermal barriers, forcing systems to consume more fuel to achieve the same process temperatures. The course provides a deep dive into the use of "Advanced NDT" (Non-Destructive Testing) and infrared thermography to identify "Energy Leaks" and structural weaknesses before they lead to catastrophic failure or excessive waste.

Coverage includes the analysis of "Steam Trap" management, piping layout optimization to minimize frictional head loss, and the role of "Refractory" materials in high-temperature furnace efficiency. The course addresses the critical challenge of "Corrosion Under Insulation" (CUI) and the implementation of maintenance strategies that protect both structural integrity and thermal performance. Participants will gain practical expertise in conducting "Static Asset Energy Audits," utilizing RBI software for energy-critical equipment, and formulating integrity roadmaps that prioritize "Thermal Tightness" as a key conservation metric.

COURSE OBJECTIVES:

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

1.  Explain the relationship between mechanical integrity and thermal efficiency.

2.  Identify the energy impact of fouling in heat exchangers and boilers.

3.  Utilize Infrared Thermography to identify insulation failure and heat leaks.

4.  Implement "Risk-Based Inspection" (RBI) for energy-critical static assets.

5.  Optimize the performance of "Steam Traps" through systematic monitoring.

6.  Design and maintain high-efficiency thermal insulation and cladding systems.

7.  Manage "Corrosion Under Insulation" (CUI) without compromising efficiency.

8.  Evaluate the impact of "Refractory" degradation on furnace and kiln performance.

9.  Conduct pressure-drop analysis in piping to minimize pumping energy waste.

10.  Utilize Advanced NDT to detect internal fouling and thickness loss.

11.  Implement "Precision Gasketing" and sealing to eliminate process leaks.

12.  Formulate a maintenance roadmap that ensures the "Thermal Integrity" of the plant.

TARGET AUDIENCE:

This course is designed for Inspection Engineers, Mechanical Engineers, Piping Specialists, Plant Maintenance Managers, Energy Auditors, and Asset Integrity Professionals in the oil and gas, chemical, and manufacturing sectors.

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.