COURSE OVERVIEW:

Static process equipment, including pressure vessels, heat exchangers, and piping systems, forms the structural backbone of industrial facilities. This course provides a comprehensive technical guide to identifying, preventing, and repairing the mechanical degradation that threatens the integrity of these non-rotating assets. Participants will explore the physics of material failure, focusing on how internal pressure, temperature extremes, and corrosive environments contribute to thinning, cracking, and structural deformation.

The scope of this training involves a deep dive into industry-standard repair methodologies, specifically referencing ASME PCC-2 and various API codes. We will examine both temporary and permanent repair techniques, such as weld overlays, mechanical clamps, and composite wraps, and the engineering justifications required for each. Detailed coverage of nondestructive examination (NDE) techniques is provided to ensure that participants can accurately detect sub-surface flaws before they lead to catastrophic loss of containment.

Furthermore, the course emphasizes proactive failure prevention through robust inspection and material selection strategies. Attendees will learn how to interpret damage mechanism loops and implement effective corrosion management plans. By mastering the transition from flaw detection to engineered repair, technical personnel can ensure the continued safe operation of static assets, extending their service life while maintaining compliance with stringent environmental and safety regulations.

COURSE OBJECTIVES:

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

1. Identify common degradation mechanisms in static equipment and piping.
2. Apply the principles of ASME PCC-2 for the repair of pressure equipment.
3. Distinguish between temporary and permanent repair solutions.
4. Evaluate the suitability of composite wrap repairs for piping leaks.
5. Implement effective weld overlay techniques for surface restoration.
6. Interpret NDE results to determine the extent of material damage.
7. Design mechanical clamps and enclosures for on-stream leak sealing.
8. Assess the risks of stress corrosion cracking and hydrogen embrittlement.
9. Perform calculations for remaining life and minimum wall thickness.
10. Execute proper heat treatment and stress relief procedures for repairs.
11. Develop a comprehensive inspection plan based on damage mechanisms.
12. Manage the integrity of bolted flange connections and gaskets.
13. Coordinate repair activities during plant turnarounds and emergency shutdowns.

TARGET AUDIENCE:

Mechanical Engineers, Piping Engineers, Asset Integrity Specialists, Inspection Personnel, and Maintenance Supervisors in the process and petrochemical industries.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.