This course will focus in the technical basis and application of ASME B31.3, B31.4 and B31.8 piping codes and API 579 Fitness-for-Service and Flaw Evaluation. This course comprises two sections; the first examines the design requirements for process plant piping systems. The second section examines the maintenance requirements for these systems.  In each case, the course goes beyond merely repeating the material contained in the governing standards.  It discusses practical applications and typical procedures. The course also contains sample problems that are put together with written exercises for the delegates.

Upon successful completion of this course, the delegates will be able to:

• Understand the total structural integrity of process plant piping systems throughout their useful life
• Gain an in-depth knowledge of pipe and fitting material specifications, fabrication process and influence on mechanical properties of strength and toughness and to help in material selection and failure analysis
• Distinguish the technical background to the design equations, and their application to the design of piping systems and pipelines. The course addresses rules of good practice in layout of piping systems for reliable operation
• Gain a practical understanding of piping and pipeline corrosion mechanisms, how to recognize them, classify them and resolve them

The course is intended for engineers, maintenance technicians and inspectors responsible for the design, integrity, maintenance and repair of pipelines and piping systems.

Day 1:

Introduction, Material and Inspections

• Introduction
• History of Pipeline Technology
• ASME Codes and Standards
• API Standards
• NACA, MSS-SP, PFI Standards
• Fundamentals of Maintenance and Integrity

• Materials
• API 5Land ASTM Specifications
• Practical Aspects of Metallurgical Properties
• Chemistry and Material Test Reports
• Fabrication of Line Pipe and Forged Fittings
• Mechanical Properties: Strength and Toughness

• Welding
• Overview of Pipe and Pipeline Welding Practice
• API 1104 and ASME IX Requirement
• Welding In-service: Challenge and Solutions

Day 2:

Integrity for Sustained Loads

• Operating and Design Pressure
• How to Establish the System Design Pressure
• Introduction to Pressure Relief Valves
• Pipe and Pipeline Sizing Formula with Applications

• Layout and Support
• Rules of Good Practice in layout
• Pump and Compressor Piping
• How to Support a piping System
• Review of Support Types and their Application
• Lesson learned from Poor Support Practices

• Temperature Effects
• Flexibility Layout Analysis
• Temperature Transients and Fatigue Damage

• Vibration in Service
• Mechanical and Hydraulic Induced Vibration in Piping
• How to Measure Analyze Resolve Vibration

Day 3:

Integrity for Occasional Loads

• Pressure Transients
• Recognizing and Solving Liquid Hammer
• Pump Station Transients
• Study of Pipeline Failures Due to Transient
• Two-Phase Liquid -Vapor Transients
• Two-Phase Liquid-Gas Transients
• Gas Discharge Transients

•  Buried Pipe
• Soil Loads
• Surface Loads
• Expansion of Buried Pipe
• Soil settlement
• n-service Movement of Pipeline

• Pipeline Failures
• Study Case Histories
• Understanding Why Failures Occur and How to Avoid Them

Day 4:

Piping System Maintenance

• Flange and Mechanical Joints
• Overview of Different Types of Flanges and Application
• Gasket of Bolt Selection
• Causes of Flange Leaks and How to Resolve
• Case Study of Flange Failure
• Assembly of Flange Joints and Leak Tightness

• Pressure and Leak Testing
• The Difference Between Leak Testing and Pressure Testing
• Review of Difference Testing Techniques
• The Purpose of Hydro test
• How to Conduct a Hydro test
• Pipeline and Piping Systems Testing
• Pneumatic Testing

• Repair Techniques
• The New ASME Repair Standards
• The Fundamentals of Repair package
• Pipe and Component Replacement
• Grinding and welding
• Welded Sleeve: Type A and B
• Flush Patch Repair
• Fillet Welded Patch
• Weld Overlay Repair
• Mechanical Clamp with Sealant Injection
• Mechanical Clamp without Sealant Injection
• Insertion Liners
• Painted and Brushed Liners
• Pipe Coating

Day 5:

Corrosion, Assessment and Repairs

• Corrosion
• Introduction to Practical Corrosion
• Classification of Corrosion Mechanisms
• General wall Thinning
• Local Corrosion: Galvanic Effects
• Crevice corrosion
• Pitting Corrosion
• Environmental Effects
• Hydrogen and H2s Effects
• Microbiological Corrosion
• Corrosion Protection
• Cathodic protection Overview

• Mechanical damage To Pipelines
• Dents and Gouges
• Ripples and buckles

• Fitness for Service Overview
• Application of ASME B31G to Determine Remaining Life
• Application of 579 to General and Local Corrosion
• Analysis of Dents and Gouges in Pipelines
• How to Evaluate cracks in piping and Pipelines

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session