COURSE OVERVIEW:

The operational life of a pressure vessel is often challenged by degradation mechanisms that can compromise its structural integrity. This course provides an advanced technical framework for managing in-service pressure vessels, centered on the American Petroleum Institute (API) 510 code. Participants will navigate the critical process of identifying flaws such as local thinning, pitting, and cracking and determining if the equipment remains safe for continued operation through Fitness-For-Service (FFS) assessments according to API 579-1/ASME FFS-1.

The curriculum bridges the gap between raw inspection data and engineering decision-making. We will explore the three levels of FFS assessment, from simple conservative calculations to advanced stress analysis. Attendees will gain expertise in evaluating the "Remaining Life" of a vessel, setting inspection intervals based on corrosion rates, and determining the Maximum Allowable Working Pressure (MAWP) for degraded components. Detailed coverage is provided on the metallurgical aspects of damage, including the impact of hydrogen attack, creep, and brittle fracture.

The final modules address the complex requirements for repairs and alterations. Participants will learn how to design and execute code-compliant repair procedures, including weld overlays, insert plates, and nozzle replacements. By emphasizing the role of the Authorized Inspector and the importance of post-repair testing, this course ensures that all modifications meet the rigorous safety standards of ASME Section VIII and the National Board Inspection Code (NBIC), ultimately preventing catastrophic failures in the plant.

COURSE OBJECTIVES:

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

1.  Apply the requirements of API 510 for in-service vessel management.

2.  Conduct Level 1 and Level 2 Fitness-For-Service (FFS) evaluations.

3.  Interpret NDT data to map metal loss and pitting patterns.

4.  Calculate the remaining life and next inspection date for pressure vessels.

5.  Evaluate the structural integrity of vessels with cracks and laminations.

6.  Distinguish between "Repairs" and "Alterations" per code definitions.

7.  Approve welding procedures and welder qualifications for vessel repairs.

8.  Assess the need for Post-Weld Heat Treatment (PWHT) after repair.

9.  Execute "Run-Repair-Replace" logic for degraded static equipment.

10.  Manage the inspection of vessels in high-temperature or sour service.

11.  Determine the impact of flaws on the vessel’s Minimum Design Metal Temperature (MDMT).

12.  Oversee the documentation and certification of vessel modifications.

13.  Coordinate with Authorized Inspectors and Jurisdictional authorities.

TARGET AUDIENCE:

Inspection Engineers, Mechanical Integrity Specialists, QA/QC Personnel, Maintenance Engineers, and Plant Managers involved in the lifecycle management of pressure equipment.

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.