COURSE OVERVIEW:

A well-designed piping system is the backbone of any process plant, requiring a balance between efficient fluid transport and ease of long-term maintenance. This course provides an integrated look at the lifecycle of industrial piping, starting with the selection of pipe schedules and fittings based on hydraulic requirements and pressure-temperature ratings. Participants will explore the logic of piping layouts, focusing on how to minimize friction losses while ensuring that all components remain accessible for inspection and repair.

Maintenance of piping systems is often overlooked until a leak or failure occurs, leading to significant safety risks. This training emphasizes the proactive management of piping assets, including the implementation of periodic wall thickness surveys and the monitoring of pipe supports. The scope covers common degradation mechanisms such as corrosion under insulation (CUI) and erosion-corrosion, providing technicians and engineers with the tools to predict and prevent failures through systematic maintenance planning.

The coverage of the course includes a detailed review of repair techniques that do not require total system shutdowns, such as the use of engineered clamps and composite wraps. Participants will also learn about the importance of effective labeling, P&ID accuracy, and the management of "dead legs" in the system to prevent localized corrosion. By combining design theory with practical maintenance applications, this course ensures that participants can maintain the mechanical integrity and operational efficiency of the plant’s piping infrastructure.

COURSE OBJECTIVES:

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

1.  Select appropriate piping materials and schedules for various process fluids.

2.  Apply the principles of fluid flow to size pipes and minimize pressure drops.

3.  Identify all piping components including elbows, reducers, and branch fittings.

4.  Interpret P&IDs and piping plot plans for maintenance and operation.

5.  Develop a preventive maintenance schedule for piping systems and supports.

6.  Diagnose the causes of internal and external corrosion in process piping.

7.  Execute wall thickness measurements using ultrasonic testing equipment.

8.  Manage "Dead Legs" and stagnant zones to prevent microbiologically induced corrosion.

9.  Inspect and maintain pipe hangers, shoes, and sliding supports.

10.  Evaluate the suitability of temporary repair methods versus permanent fixes.

11.  Implement a labeling and color-coding system for industrial piping.

12.  Prepare piping systems for safe entry, isolation, and maintenance.

13.  Coordinate the replacement of piping spools during planned turnarounds.

TARGET AUDIENCE:

Maintenance Technicians, Piping Designers, Plant Engineers, and Inspection Personnel responsible for the upkeep of fluid transport systems.

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.