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ICTD International Centre for Training and Development

Plant Piping Systems: Operation, Maintenance and Repairs

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This course introduces operations, engineering, maintenance, and inspection personnel to the technical bases for safely and cost-effectively operating, maintaining and troubleshooting plant piping systems. Practical case studies are used to illustrate the rules for assessing the integrity of operating systems, evaluating degraded conditions, and specifying maintenance and repair options. The course builds upon the fundamental rules of the ASME Code and their application to operating systems. Topics that will have the main focus are:

  • The application of the ASME codes for design (ASME B31), fitness-for-service (ASME FFS) and inspection and repairs (ASME PCC) of piping systems in operating plants
  • The assessment and retrofit of systems in operating plants through case studies of degradation mechanisms, inspections, evaluation, fitness-for-service and run-orrepair
  • The technical basis and margins of the fitness for service criteria for the different classes of degradation mechanism
  • The new standard ASME Post-Construction Code PCC-2, applied to the repair of piping system and components

Course Objectives

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

  • Identify the relevant codes, standards and industry guides
  • Describe the process of material selection and properties
  • Describe the process of selection and sizing pipe and fittings
  • Explain the maintenance inspection techniques
  • Identify methods for hydrostatic and leak testing
  • Describe the process of classification and evaluation of corrosion
  • Explain the evaluation of crack flaws and mechanical damage


Day 1

  • Overview of Codes and Standards:
  • Design
  • Inspection
  • Fitness-for-Service
  • Design Bases
  • Service Conditions
  • Plant Piping Specifications
  • Applicable ASME Code and Industry Guide
  • Industry Best Practice and Applications
  • Six fundamental aspects of Piping Systems Integrity

Day 2

  • Maintenance and Repair Work Packages
  • Design Margins vs. Operational Margins
  • Wall Thinning Corrosion Mechanisms
  • Fitness-for-Service Evaluation of Corroded Piping and Components
  • Case Histories
  • Cracking Mechanisms and Crack-Like Defects
  • Fitness-for-Service Evaluation of Crack-Like Flaws in Piping and Components

Day 3

  • Case Histories
  • Embrittlement and Creep Mechanisms
  • Remaining Life Evaluation of Piping in the Creep Regime
  • Mechanical Damage
  • Fitness-for-Service Evaluation of Piping with Mechanical Damage
  • Case Histories
  • Flow-Induced Vibration:
  • Causes
  • Assessment
  • Resolution

Day 4

  • Water hammer:
  • The Four Classes of Transients; Causes, Assessment, Resolution
  • Risk-Based Inspection Techniques
  • Repair Codes and Standards
  • Welded Repairs
  • Non-Welded Repairs
  • Examination and Testing of Repairs
  • Repair Packages and Management of Change

Day 5

  • Case Histories of Classic Accidents Due to Poor Management of Change
  • Operating Strategies
  • Review of Requirements of API 570
  • Operator Competencies Requirements
  • Maintenance Practices and Procedures
  • Maintenance and Inspection
  • Maintenance Repair

Who should attend

This course is intended for operations, engineering, inspection and quality personnel responsible for specifying, operating, inspecting and maintaining piping systems.


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