Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical and Maintenance Engineers
• Reliability and Integrity Engineers
• Piping and Inspection Engineers
• Plant and Operations Engineers
• Maintenance Supervisors and Technicians
• Anyone involved in piping system maintenance, operation, or inspection

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand piping system design and operational principles
• Identify common failure mechanisms in plant piping
• Apply inspection, monitoring, and maintenance techniques
• Recognize corrosion and stress-related damage modes
• Conduct root cause analysis and implement preventive actions
• Improve piping reliability through integrity management programs

DAY 1

Introduction to Piping Systems and Design Fundamentals

• Welcome and Introduction
• Pre-Test
• Overview of Industrial Piping Systems and Layouts
• Piping Materials and Standards (ASME B31.1, B31.3, API)
• Pressure, Temperature, and Flow Considerations
• Piping Stress, Flexibility, and Support Concepts
• Design Safety and Operating Parameters

DAY 2

Operation and Control of Piping Systems

• Start-up, Normal Operation, and Shutdown Procedures
• Fluid Flow Dynamics and Pressure Control
• Thermal Expansion and Stress Effects
• Interaction Between Piping, Valves, and Equipment
• Vibration in Piping Systems – Causes and Control
• Temperature and Pressure Monitoring Techniques
• Leak Detection and Operational Safety

DAY 3

Inspection and Maintenance Practices

• Preventive and Predictive Maintenance Strategies
• In-Service Inspection and Testing Procedures
• Visual and Non-Destructive Testing (NDT) Techniques
• Thickness Measurement and Corrosion Mapping
• Flange, Gasket, and Bolt Inspection
• Maintenance Planning and Documentation
• Pipe Support and Alignment Maintenance

DAY 4

Failure Mechanisms and Integrity Management

• Common Piping Failures – Fatigue, Creep, and Corrosion
• Stress Corrosion Cracking and Erosion-Corrosion
• Water Hammer and Pressure Surge Failures
• Root Cause Failure Analysis (RCFA)
• Fitness-for-Service (FFS) Assessments (API 579)
• Risk-Based Inspection (RBI) Concepts
• Strategies for Failure Prevention and Life Extension

DAY 5

Troubleshooting and Course Wrap-up

• Case Studies of Piping Failures and Lessons Learned
• Troubleshooting Operational and Structural Problems
• Piping Integrity and Reliability Improvement Techniques
• Post-Test
• Certificate Ceremony