FE020

Pipeline and Piping

Inspection, Maintenance,
Repair & Integrity Assessment

H.H. Dhabi
Sheik–Sultan
U.A.E |Tower (0) Floor
www.ictd.ae | Corniche Street
| [email protected] | Abu Dhabi – U.A.E | www.ictd.ae | [email protected]
Course Introduction:
This course on the practical aspects of piping and pipeline design, integrity, maintenance and repair.
The participants will obtain an in-depth understanding of the ASME B31 code rules and API
standards, their technical basis and practical application to field conditions.

The course reviews and applies the ASME code design rules, strength and fracture design analysis
and acceptance criteria.

The participants will be able to recognize causes of degradation in-service, whether mechanically
induced (pressure, vibration, fatigue, pressure transients, external damage) or due to corrosion (wall
thinning, pitting, cracking), and apply integrity analysis techniques to make run-or-repair decisions.

The participants will review inspection techniques, from the most common (PT, MT, UT, RT, MFL
pigs) to most recent (AE, PED, UT pigs and multi pigs), and the implementation of integrity
management programs, periodic inspections and evaluation of results.

The course will review the various repair techniques, their advantages and shortcomings, and the
step-by-step logic to be followed in making repair decisions and selecting the applicable repair.

Course Objectives:
Upon successful completion of this course, the delegates will be able to:
 Acquire an in-depth understanding of the ASME B31 design, construction, inspection and
testing rules as well as their application to integrity assessment of operating systems
 Gain an in-depth knowledge of pipe and fitting material specifications, fabrication process
and influence on mechanical properties of strength and toughness to help in material
selection and failure analysis
 Understand the technical background to the design equations, and their application to the
design of piping systems and pipelines
 Recognize rules of good practice in layout of piping systems for reliable operation
 Apply step-by-step review of operating transients in piping systems and pipelines, their
cause and the methods for their analysis
 Apply construction and welding practices, weld inspections, weld flaws and acceptance
criteria and carryout hydro testing methods and alternative leak detection techniques
 Gain a practical understanding of piping and pipeline corrosion mechanisms, how to
recognize them, classify them and resolve them
 Introduce the latest techniques and research in piping and pipeline integrity to analyze a
degraded condition due to the latest to either corrosion or mechanical damage
 Review case histories of field failures and will evaluate their cause and solutions to avoid
recurrence

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

Course Outline:

Day 1:
Materials and Sizing
Introduction
 History of Pipeline Technology
 ASME Codes and Standards
 API Standards
 NACE, 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

Operating and Design Pressure

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

Integrity for sustained loads

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
 Lessons Learned from Poor Support Practices

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Day 2:

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

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

Integrity for Occasional Loads

Pressure Transients
 Recognizing and Solving Liquid Hammer
 Pump Station Transients
 Study of Pipeline Failures Due to Transients
 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
 In-Service Movement of Pipeline

Day 3:

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

Material Flaws and Inspections

Welding
 Overview of Pipe and Pipeline Welding Practice
 API 1104 and ASME IX Requirements
 Welding In-Service: Challenge and Solutions

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Inspection
 Weld Inspection Techniques
 Pigging Technology: Overview of Utility and Smart Pigs
 Overview of Regulations for In-Line Inspections

Day 4:

Flange and Mechanical Joints

 Overview of Different Types of Flanges and Application
 Gasket and 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 Different Testing Techniques
 The Purpose of Hydrotest
 How to Conduct a Hydrotest
 Pipeline and Piping Systems Testing
 Pneumatic Testing

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

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Day 5:

Mechanical Damage to Pipelines

 Dents and Gouges
 Ripples and Buckles

Fitness-for-Service Overview
 Application of ASME B31G to Determine Remaining Life
 Application of API 579 to General and Local Corrosion
 Analysis of Dents and Gouges in Pipelines
 How to Evaluate Cracks in Piping and Pipelines

Repair Techniques
 The New ASME Repair Standards
 The Fundamentals of Repair Packages
 Pipe and Component Replacement
 Grinding and Welding
 Welded Sleeve: Type A and Type 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

Course Certificate:
International Center for Training & Development (ICTD) will award an internationally recognized
certificate(s) for each delegate on completion of training.

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Course Methodology:
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

Course Fees:
To be advised as per the course location. This rate includes participant’s manual, hand-outs,
buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings:
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

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