Asset Integrity Management: Design Integrity

5-Day Professional Training Course

Course Overview

This 5-day Design Integrity course provides comprehensive knowledge of integrity management principles from concept through construction. Covers design standards, risk assessment, materials selection, quality assurance, and lifecycle integration for oil & gas, petrochemical, and process industries.

Target Audience: Design engineers, project engineers, asset integrity engineers, process safety engineers, materials engineers, project managers, and integrity professionals.

5-Day Course Outline

Day 1: Fundamentals and Regulatory Framework

Morning:

• Asset integrity management overview

• Design vs. operational integrity

• Major incident lessons (Piper Alpha, Buncefield, Texas City)

• Regulatory framework: OSHA PSM, COMAH, EPA RMP

• Industry standards: API, ASME, ISO 55000, IEC 61508/61511

Afternoon:

• Design integrity philosophy and principles

• Inherently safer design concepts

• Hierarchy of controls

• Design basis documentation

• Configuration management

• Design for operability, maintainability, inspectability

Day 2: Process Safety and Risk Assessment

Morning:

• Process Safety Management (PSM) in design

• Safety Instrumented Systems (SIS) and SIL determination

• Layers of Protection Analysis (LOPA)

• HAZID methodology and workshops

• HAZOP studies and facilitation

Afternoon:

• Risk assessment methodologies (ISO 31000)

• Consequence and frequency analysis

• Risk matrices and ALARP principle

• Major accident hazard scenarios

• Safety-critical elements (SCE)

• Emergency shutdown (ESD) and blowdown systems

Workshop: HAZOP exercise on sample P&ID

Day 3: Materials and Equipment Design

Morning:

• Materials selection methodology

• Corrosion mechanisms (API RP 571 overview)

• Material properties and standards (ASTM, ASME)

• Corrosion allowance determination

• Pressure vessel design (ASME Section VIII)

• Piping design (ASME B31.3)

Afternoon:

• Rotating equipment design integrity (API 610, 617, 682)

• Static equipment: heat exchangers, tanks (API 650/653)

• Structural integrity considerations

• Pump and compressor materials selection

• Design for special services (high-temp, cryogenic, sour service)

Workshop: Materials selection exercise

Day 4: Verification and Quality Assurance

Morning:

• Design review stages (conceptual, FEED, detailed)

• Design verification and validation

• Peer reviews and third-party verification

• Quality management systems (ISO 9001)

• Inspection and test plans (ITP)

• Factory acceptance testing (FAT)

Afternoon:

• Welding design and fabrication integrity

• Welding procedures (WPS, PQR, WQT)

• Non-destructive examination (NDT): VT, RT, UT, MT, PT

• Pre-commissioning and mechanical completion

• Pre-startup safety review (PSSR)

• Handover to operations

Workshop: Design review simulation

Day 5: Management Systems and Integration

Morning:

• Management of Change (MOC) processes

• MOC triggers, categories, and documentation

• ISO 55000 Asset Management framework

• Integrity Operating Windows (IOW)

• Performance standards and KPIs

• Barrier management

Afternoon:

• Design for inspection and maintenance

• Risk-Based Inspection (RBI) considerations (API 580/581)

• Maintainability and reliability design

• Digital engineering: BIM, digital twins, IoT

• Industry 4.0 and smart assets

• Case studies: major accident lessons learned

Final Exam: 60 questions, 2 hours, 70% pass
Certificate Presentation

Learning Outcomes

✅ Apply integrity management principles across asset lifecycle
✅ Conduct hazard identification and risk assessments
✅ Select materials per API, ASME standards
✅ Apply pressure vessel and piping design codes
✅ Implement quality assurance programs
✅ Manage design changes through MOC
✅ Design for inspectability and maintainability
✅ Integrate design with operational integrity

Course Features

Materials: 600+ page manual, standards guides, checklists, USB resources
Assessment: Workshops, written exam, design reviews
Certification: 40 CPD/CEU hours, globally recognized certificate
Method: 60% theory, 40% practical workshops

Who Should Attend

• Design engineers (process, mechanical, civil)

• Project engineers and managers

• Asset integrity engineers

• Process safety engineers

• Materials/corrosion engineers

• Inspection engineers

• EPC contractors

• Integrity consultants

Prerequisites: Engineering degree + 3 years experience OR technical diploma + 5 years experience

 Keywords

Primary: Asset integrity management, Design integrity course, Engineering design training, Process safety design, Lifecycle integrity management

Secondary: Design verification, Materials selection, Quality assurance design, MOC management, Construction integrity

Long-tail: 5-day asset integrity design course, Engineering design integrity training oil gas, Process plant design integrity certification, Design phase integrity management professional training

Investment

Includes: Training, manual, tools, certificate, meals, digital resources

Discounts:

• 🎯 Early Bird: 20% (60+ days)

• 🎯 Group: 15-20% (3+ participants)

• 🎯 Alumni: 25% off

Custom in-house training available

Why Choose This Course

✓ ISO 55000, API, ASME standards based
✓ Instructors with 20+ years experience
✓ 40% hands-on workshops
✓ Real accident case studies
✓ Globally recognized certificate
✓ Practical tools and templates

Related Courses

• Asset Integrity: Operational Integrity (5 days)

• API 580/581 Risk-Based Inspection (5 days)

• API 579 Fitness-for-Service (5 days)

• Process Safety Management (5 days)

• HAZOP Study Leadership (3 days)

Testimonials

“Outstanding course bridging design and integrity. Should be mandatory for all design engineers.” — Senior Design Engineer, EPC Contractor

“Comprehensive coverage with practical tools I use daily in design reviews.” — Mechanical Engineer, Consulting Firm