Plant Piping & Pipeline Systems (Design and Integrity): Professional 5-Day Training Course

Course Overview

The Plant Piping & Pipeline Systems (Design and Integrity) course is a comprehensive 5-day professional training program designed for engineers, designers, and technical professionals involved in the design, construction, operation, and integrity management of industrial piping systems. This intensive training covers the complete spectrum of plant piping design, from initial layout and stress analysis through material selection, fabrication, and long-term integrity assurance. Participants will gain specialized knowledge in applying industry codes and standards, performing piping stress analysis, implementing fitness-for-service assessments, and developing risk-based inspection programs for process plant piping systems.

Industrial piping systems represent the circulatory network of process facilities, refineries, chemical plants, power generation facilities, and manufacturing operations worldwide. With aging infrastructure, increasingly stringent safety regulations, and demanding operational conditions, the need for qualified professionals in piping integrity management and advanced design continues to grow exponentially. This course addresses critical industry challenges by integrating piping design fundamentals, stress analysis techniques, materials engineering, inspection methodologies, and integrity management strategies that ensure safe, reliable, and compliant piping operations throughout the asset lifecycle.

Target Audience

This comprehensive course is specifically designed for:

• Piping design engineers and designers

• Plant engineers and maintenance supervisors

• Mechanical integrity engineers

• Stress analysis engineers

• Materials and corrosion engineers

• Inspection engineers and technicians

• Plant reliability engineers

• Asset integrity managers

• Project engineers in process industries

• Quality assurance and quality control professionals

• EPC contractors and consultants

• Regulatory compliance specialists

Day 1: Piping Design Fundamentals and Code Requirements

Morning Session: Introduction to Plant Piping Systems and Industry Standards

The opening day establishes the foundation for plant piping design by exploring fundamental concepts, system classifications, and the comprehensive regulatory framework governing industrial piping installations. Participants begin with an overview of piping system components, design philosophies, and the critical distinctions between various piping codes applicable to process plant applications across oil and gas, petrochemical, power generation, and manufacturing sectors.

Key Topics:

• Introduction to plant piping and pipeline systems in process facilities

• Piping system classifications: process piping, utility piping, and auxiliary systems

• Industry codes and standards overview: ASME B31.1, B31.3, B31.4, B31.8

• ASME B31.3 Process Piping Code: scope, applicability, and requirements

• International standards: ISO, EN, and regional code variations

• Design responsibilities and jurisdictional boundaries

• Piping components: pipes, fittings, flanges, valves, and specialty items

• Piping specifications and material class development

• Project documentation: P&IDs, piping layout drawings, and isometric drawings

• Design basis and process data requirements for piping design

Afternoon Session: Piping Layout, Routing and 3D Design

Piping layout design requires systematic planning to optimize space utilization, maintainability, and operational efficiency while ensuring safety and code compliance. This session covers piping arrangement principles, routing guidelines, equipment interface considerations, and modern 3D design software applications that enhance design quality and reduce construction conflicts.

Key Topics:

• Piping layout fundamentals and general arrangement principles

• Equipment layout and spacing requirements

• Piping routing guidelines: above-ground, underground, and rack systems

• Pipe support design philosophy and spacing requirements

• Clearances for operation, maintenance, and inspection access

• Thermal expansion considerations in piping layout

• 3D plant design software: PDMS, E3D, SmartPlant, and AutoCAD Plant 3D

• Clash detection and design coordination

• Constructability reviews and design optimization

• As-built documentation and model validation

• Interface management: civil, structural, electrical, and instrumentation disciplines

Day 2: Material Selection, Wall Thickness and Stress Analysis Fundamentals

Morning Session: Piping Materials and Selection Criteria

Day two focuses on piping materials engineering, covering material properties, selection methodologies, and compatibility considerations essential for reliable piping system performance. Participants explore various metallic and non-metallic materials, corrosion mechanisms, and material testing requirements that ensure appropriate material selection for specific service conditions.

Key Topics:

• Carbon steel piping materials: ASTM A106, A53, API 5L specifications

• Alloy steel materials: chrome-moly and high-temperature applications

• Stainless steel piping: austenitic, ferritic, and duplex grades

• Non-ferrous materials: copper, aluminum, and nickel alloys

• Non-metallic piping: FRP, HDPE, PVC, and thermoplastic applications

• Material selection criteria: temperature, pressure, corrosivity, and economics

• Material impact testing and notch toughness requirements

• High-energy piping systems and material considerations

• Dissimilar metal welding and galvanic corrosion

• Material traceability and positive material identification (PMI)

• Special materials for severe service applications

Afternoon Session: Pressure Design and Wall Thickness Calculations

Wall thickness determination represents a fundamental aspect of piping design, ensuring structural integrity under operating conditions. This session provides comprehensive training on pressure design equations, allowable stress values, design factors, and the application of ASME B31.3 code requirements for calculating minimum required thickness for straight pipe, bends, and branch connections.

Key Topics:

• ASME B31.3 pressure design fundamentals and philosophy

• Straight pipe thickness calculation: internal pressure formula

• Allowable stress values and temperature derating

• Design pressure and temperature determination

• Corrosion allowance and mill tolerance considerations

• Pipe schedule selection and standard dimensions

• Branch connection reinforcement requirements

• Thickness calculations for bends, reducers, and fittings

• External pressure design and vacuum conditions

• High-pressure piping systems: special considerations

• Piping wall thickness calculation software tools

Day 3: Piping Stress Analysis and Flexibility Design

Morning Session: Piping Stress Analysis Fundamentals

Piping stress analysis ensures that piping systems can safely accommodate thermal expansion, pressure loads, external forces, and equipment movements without excessive stresses or detrimental effects on connected equipment. This session introduces stress analysis principles, failure modes, and the systematic approach to evaluating piping flexibility and support requirements.

Key Topics:

• Introduction to piping stress analysis and objectives

• Stress categories: primary, secondary, and peak stresses

• ASME B31.3 allowable stress criteria and stress intensification factors

• Thermal expansion calculations and displacement analysis

• Flexibility analysis requirements and exemption criteria

• Sustained loads: weight, pressure, and external forces

• Occasional loads: wind, earthquake, and relief valve reaction forces

• Equipment nozzle loads and allowable limits

• Pipe support design: types, locations, and load calculations

• Guided cantilever method for preliminary flexibility assessment

• Introduction to pipe stress analysis software: CAESAR II and AutoPIPE

Afternoon Session: Advanced Stress Analysis and Software Applications

Participants gain hands-on experience with pipe stress analysis software, learning to build piping models, apply loads and boundary conditions, interpret analysis results, and optimize piping configurations. This practical session covers modeling techniques, troubleshooting high-stress areas, and generating comprehensive stress analysis reports.

Key Topics:

• CAESAR II software: modeling techniques and input requirements

• Piping system modeling: geometry, materials, and operating conditions

• Boundary conditions: anchors, supports, and equipment connections

• Load case definition: operating, sustained, thermal, and occasional loads

• Static and dynamic analysis execution

• Stress analysis results interpretation and code compliance verification

• Identifying and resolving overstressed conditions

• Support optimization and load distribution

• Nozzle load extraction and equipment interface verification

• Fatigue analysis for cyclic loading conditions

• Dynamic analysis: harmonic, response spectrum, and time-history methods

• Stress analysis reporting and documentation requirements

Day 4: Fabrication, Inspection and Quality Assurance

Morning Session: Piping Fabrication and Welding Technology

Quality piping fabrication ensures that design intent is realized through proper material handling, fabrication techniques, and welding practices. This session covers fabrication procedures, welding processes, joint preparation, heat treatment requirements, and quality control measures essential for producing reliable piping systems meeting code requirements and project specifications.

Key Topics:

• Piping fabrication procedures and shop practices

• Welding processes for piping: SMAW, GTAW, GMAW, and FCAW

• Welding procedure specifications (WPS) and procedure qualification records (PQR)

• Welder performance qualifications (WPQ) and certification

• Weld joint design and preparation requirements

• Pre-heating and post-weld heat treatment (PWHT) requirements

• Weld quality requirements: visual acceptance criteria

• Backing rings, consumable inserts, and root pass techniques

• Branch connection fabrication: weldolets, sockolets, and reinforcement pads

• Shop fabrication versus field fabrication considerations

• Dimensional control and fit-up tolerances

Afternoon Session: Non-Destructive Examination and Inspection Planning

Non-destructive examination (NDE) provides critical verification of weld quality and material integrity without damaging piping components. This session explores various NDE methods, examination requirements per ASME codes, qualification standards, acceptance criteria, and inspection planning strategies that ensure comprehensive quality assurance throughout fabrication and construction.

Key Topics:

• Non-destructive examination overview and selection criteria

• Radiographic testing (RT): film and digital radiography techniques

• Ultrasonic testing (UT): conventional and phased array applications

• Magnetic particle testing (MT) for surface crack detection

• Liquid penetrant testing (PT) for non-magnetic materials

• Visual testing (VT) and inspection acceptance standards

• NDE personnel qualification: ASNT SNT-TC-1A and ISO 9712

• ASME B31.3 examination requirements: normal, severe, and special service

• Random examination versus 100% examination requirements

• Acceptance criteria and defect evaluation

• Positive material identification (PMI) programs

• Documentation and record-keeping requirements

Day 5: Piping Integrity Management and Fitness-for-Service Assessment

Morning Session: In-Service Inspection and Risk-Based Inspection

Day five addresses piping integrity management, focusing on systematic approaches to maintaining piping system reliability through effective inspection programs. Participants explore risk-based inspection (RBI) methodologies, inspection planning, damage mechanisms, and regulatory compliance requirements that optimize inspection resources while ensuring safety and reliability.

Key Topics:

• Piping integrity management framework and regulatory drivers

• API 570 Piping Inspection Code: scope and requirements

• Inspection planning and interval determination

• Damage mechanisms in process piping: corrosion, erosion, and cracking

• Corrosion under insulation (CUI) detection and management

• Risk-based inspection (RBI) methodology: API 580 and API 581

• Probability of failure (POF) and consequence of failure (COF) assessment

• Inspection data management systems

• Thickness monitoring programs and inspection circuits

• Fixed piping inspection: access considerations and scaffolding requirements

• Inspection technologies: conventional UT, PAUT, and long-range UT (LRUT)

• Regulatory compliance: OSHA PSM and EPA RMP requirements

Afternoon Session: Fitness-for-Service Assessment and Remaining Life Evaluation

Fitness-for-service (FFS) assessment provides engineering-based evaluations to determine whether piping containing flaws or damage can continue operating safely. This session covers API 579-1/ASME FFS-1 standard, various assessment levels, and practical applications for evaluating local metal loss, cracks, dents, and other forms of degradation.

Key Topics:

• Introduction to fitness-for-service assessment: API 579-1/ASME FFS-1

• FFS assessment levels: Level 1, 2, and 3 analyses

• Local metal loss assessment: corrosion, erosion, and pitting

• Remaining strength factor (RSF) calculations

• Crack-like flaws assessment and fracture mechanics

• Laminations, blisters, and hydrogen-induced cracking (HIC) evaluation

• Dents, gouges, and mechanical damage assessment

• Fire damage and high-temperature exposure evaluation

• Remaining life prediction and re-inspection intervals

• Repair versus replace decision-making criteria

• Temporary versus permanent repairs

• Course review: case studies, practical exercises, and certification

Learning Outcomes

Upon completing this plant piping and pipeline systems training, participants will be able to:

• Apply ASME B31.3 and other piping codes to design projects

• Develop piping layout designs considering operational and maintenance requirements

• Select appropriate piping materials based on service conditions

• Calculate minimum required wall thickness per code requirements

• Perform piping flexibility analysis and interpret stress analysis results

• Utilize pipe stress analysis software effectively

• Understand fabrication, welding, and quality control requirements

• Plan and execute non-destructive examination programs

• Develop risk-based inspection strategies for piping systems

• Conduct fitness-for-service assessments for degraded piping

• Implement comprehensive piping integrity management programs

• Ensure regulatory compliance and industry best practices

Conclusion

This comprehensive 5-day plant piping design and integrity training equips professionals with essential competencies spanning the complete piping system lifecycle, from initial design through long-term integrity management. By integrating code requirements, engineering calculations, stress analysis techniques, fabrication quality control, inspection methodologies, and fitness-for-service assessment, participants develop holistic expertise that enhances safety, reliability, and compliance in industrial piping operations. The knowledge and practical skills acquired translate directly to improved engineering decisions, optimized maintenance strategies, reduced operational risks, and extended asset life, making participants invaluable assets to organizations operating complex process facilities in today’s demanding industrial environment.