Piping Systems: Design, Inspection and Integrity

Overview

Piping systems connect every piece of equipment in oil, gas, refining and petrochemical facilities, and they often account for a large share of loss of containment incidents. Leaks and ruptures can result from poor design, wrong materials, corrosion, erosion, vibration, fatigue, inadequate supports or mistakes during maintenance and modification. Because plants contain many kilometres of piping, operators need a systematic approach to design, inspection and integrity management that focuses effort where the risks are highest and ensures that changes do not introduce new hazards.

This course provides a practical understanding of piping system design, inspection and integrity management. Participants learn the main piping codes and design principles, pressure design of pipe and fittings, flanges, valves, branch connections and supports, and the effects of thermal expansion and flexibility. The course covers material selection, fabrication, welding and testing, and the damage mechanisms that affect process piping, including corrosion, corrosion under insulation, erosion, cracking and vibration fatigue. It also explains piping inspection planning, circuits and condition monitoring locations, non-destructive testing, remaining life calculations, fitness-for-service, repairs, small-bore connections and the management of change.

Objectives

• Explain piping codes, design principles and pressure design of components
• Describe flanges, valves, branch connections, supports and flexibility needs
• Select piping materials and apply fabrication, welding and testing rules
• Identify damage mechanisms that affect process piping systems
• Plan piping inspections using circuits and condition monitoring locations
• Calculate remaining life and apply fitness-for-service and repair methods
• Manage small-bore connections, vibration risks and changes to piping

Who should attend

Training methodology

The course combines explanation of codes and principles with worked calculations, real piping drawings, isometrics and inspection data. Participants calculate pipe wall thickness, review support and flexibility arrangements, select materials for different services, define piping circuits and condition monitoring locations and calculate corrosion rates and remaining life from thickness data. Photographs of piping failures help participants recognise damage mechanisms and poor practices. Small-bore connection and vibration assessments are practised. Case studies of piping failures in refineries and gas plants are analysed in groups. Each day ends with a short quiz.

Programme outline

Dates and fees

Certificate

Frequently asked questions