🎯 Course Description:
This 5-day practical course is designed for professionals involved in the inspection, maintenance, integrity assessment, and repair of static and rotating equipment in industrial plants such as refineries, petrochemical facilities, power plants, and process industries.
Participants will gain a solid foundation in inspection techniques, damage mechanisms, failure modes, repair methods, and fitness-for-service evaluation, all aligned with key standards such as API 510, API 570, API 653, ASME, and NBIC. The course is heavily focused on real-world scenarios, case studies, and practical decision-making to ensure plant reliability and compliance.
👥 Who Should Attend:
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Plant inspectors and QA/QC engineers
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Maintenance and reliability professionals
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Integrity and asset managers
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Mechanical and process engineers
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Shutdown/turnaround planners
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Professionals preparing for API 510, 570, or 653 certifications
🗓️ Day 1: Plant Equipment Overview and Inspection Fundamentals
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Objectives, Participant Introductions |
| 09:00 – 10:30 | Types of Plant Equipment – Vessels, tanks, piping, exchangers, rotators |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Basic Inspection Terminology and Responsibilities |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Inspection Planning & Risk-Based Inspection (RBI) – API 580 Overview |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Hands-On Exercise: Developing an inspection plan for critical equipment |
🗓️ Day 2: Damage Mechanisms and Condition Monitoring
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Common Damage Mechanisms – Corrosion, cracking, erosion, creep, fatigue |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Condition Monitoring Techniques – Vibration, thermography, oil analysis |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Corrosion Monitoring and MIC Detection |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Identifying damage mechanisms based on service environment |
🗓️ Day 3: Inspection Techniques and Tools
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Visual Inspection & Checklist Development |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Non-Destructive Testing (NDT) – UT, RT, MT, PT, AE, PMI overview |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | In-Service Inspection Guidelines – API 510 (vessels), 570 (piping) |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Exercise: Interpreting inspection reports and defect evaluation |
🗓️ Day 4: Repair Techniques and Alterations
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Welding Repairs & Weld QA/QC – Procedure qualification, PWHT, hardness testing |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Repair Methods – Mechanical clamps, sleeves, composite wraps, weld overlays |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Pressure Testing After Repairs – Hydrotesting, pneumatic, leak tests |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Evaluating repair scenarios and recommending best practices |
🗓️ Day 5: Fitness-for-Service, Documentation, and Assessment
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Fitness-for-Service Overview – API 579 Levels 1–3 |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Documentation & Compliance – Inspection reports, repair records, data logs |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Mock Assessment / Knowledge Check – Based on API and ASME codes |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Final Q&A, Feedback, Action Plan, Certificate Distribution |
📂 Materials Provided:
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Plant Inspection & Repair Reference Manual
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Inspection Checklist Templates for Vessels, Piping, and Tanks
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Damage Mechanism Identification Guide (per API 571)
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Welding Repair Guidelines and Inspection Flowcharts
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Mock Exam (multiple choice with answer key)
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API Code Summary Sheets (510, 570, 579, 653)
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Certificate of Completion
