COURSE OVERVIEW:

The structural and operational integrity of piping systems and valves is fundamental to the safety and productivity of industrial process plants. This course provides a comprehensive technical exploration of how piping networks are engineered to transport fluids under varying pressures and temperatures while resisting mechanical fatigue and chemical degradation. Participants will analyze the critical relationship between material selection, pipe routing, and the stresses imposed by thermal expansion and hydraulic transients.

Construction and installation phases are scrutinized to ensure that theoretical designs are translated into high-quality physical assets. This training covers the rigorous standards for welding, flange management, and the assembly of complex valve configurations to prevent fugitive emissions and catastrophic leaks. The scope includes a detailed look at international codes such as ASME B31.3, providing a framework for verifying that every joint and support meets the safety requirements necessary for high-stakes environments.

The operational and integrity management portion of the course focuses on the lifecycle of these assets, from initial commissioning to long-term maintenance. Attendants will explore modern diagnostic tools for monitoring corrosion, erosion, and valve seat leakage, ensuring that potential failures are identified before they occur. By integrating design principles with practical maintenance strategies, this course empowers personnel to maintain system reliability, extend asset life, and ensure full compliance with evolving environmental and safety regulations.

COURSE OBJECTIVES:

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

1.  Apply the principles of ASME B31.3 for the design and inspection of process piping.

2.  Select appropriate pipe materials based on fluid chemistry and temperature limits.

3.  Identify the functional differences and applications of various valve types, including ball, gate, and globe.

4.  Calculate the required wall thickness for pipes subjected to high internal pressures.

5.  Evaluate the impact of thermal expansion on piping layout and support design.

6.  Execute proper flange bolt torquing procedures to ensure leak-free connections.

7.  Diagnose the root causes of valve seat leakage and mechanical actuator failure.

8.  Utilize non-destructive testing (NDT) methods to assess weld and pipe wall integrity.

9.  Design effective piping support systems to manage sustained and occasional loads.

10.  Implement a Risk-Based Inspection (RBI) program for piping and valve assets.

11.  Troubleshoot hydraulic water hammer and vibration issues within the piping network.

12.  Manage the selection and installation of gaskets and packing for high-pressure service.

13.  Analyze the impact of corrosion mechanisms such as CUI and pitting on system life.

TARGET AUDIENCE:

Piping Engineers, Mechanical Designers, Plant Maintenance Technicians, Quality Control Inspectors, and Asset Integrity Managers.

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.