Design and Integrity Stress Analysis of Piping Systems and Pipelines

Introduction

This course comprises two sections.  The first examines the design requirements for process plant piping systems. The second section examines the maintenance requirements for these systems. In each case, the course goes beyond merely repeating the material contained in the governing standards. It discusses practical applications and typical procedures. The course also contains sample problems that are put together with written exercises for you to complete.

Objectives

This is an introductory course to provide a basic understanding of the fabrication, inspection and testing portions of ASME B31.3 for new construction and how they work with API 570 for post-construction inspection, repairs and alterations. An important part of achieving these objectives is covering the Alberta Safety Code Act and Pressure Equipment Safety Regulations that ABSA administers in Alberta. The ABSA forms for design registration, completion of construction, data reports, and others will be reviewed. The course also includes an introduction to ASTM material standards and a brief introduction to ASME Section IX - Welding Qualifications.

• Understand the total structural integrity of process plant piping systems throughout their useful life
• Discover how the ASME B31.3 code has been correctly and incorrectly applied.
• Ensure the total structural integrity of process plant piping systems throughout their useful life.
• Discuss and apply the design requirements of the ASME B 31.3 Code.
• Achieve higher levels of maintenance excellence in refineries and other process plants.
• Examine and apply the maintenance and inspection requirements of API 570 to process plant piping systems.
• Perform engineering audits of designs and procedures

Training Methodology

The course will be conducted along with workshop principles with formal lectures and interactive worked examples and with an active contribution by all delegates during workshops and discussions and teamwork. Real-life examples will be selected to illustrate the procedure for control of good performance of gas turbines. The emphasis will be on the explanation of technical phenomena and providing answers to problems that are encountered in everyday industrial practice. There will be ample opportunities for problem solving and workshops with active open discussion and sharing professional experiences on the operation, maintenance and troubleshooting. All course materials will be provided.

Who Should Attend?

Inspectors, engineers, maintenance and QA personnel who work for owner-user companies, inspection companies, fabricators, maintenance service and repair companies, inspection companies and EPC's from petrochemical plants, refineries, power plants, gas/oil pipeline companies, and pulp mills. Optional evening tutorial sessions will be available for CSA W178.2 welding inspector exam candidates (level 1 ASME B31.3).

Course Outline

Introduction to Laws, Regulations, Jurisdiction and
Related Codes and Standards
- CSA B51-03 Boiler, Pressure Vessel, and Pressure Piping Code
- Alberta Safety Code Act
- Alberta Pressure Equipment Safety Regulation
- Alberta Pressure Welders Regulation
- Certificates of Authorization Permit and Inspection Permit
- ABSA's Role as the Jurisdiction Administrator and Authorized Inspection Agency
- ABSA Piping Forms
- AB-31 Design Registration Application
- AB-41 Statutory Declaration Form for Registration of Fittings
- AB-81 Completion of Construction Declaration
- AB-83 Construction Data Report for Piping Systems (By Manufacturers from Alberta)
- AB-83F Construction Data Report for Piping Systems (By Manufacturers Outside Alberta)
- AB-96 General Engineering Requirements for Design and Construction of Pressure Piping
  Systems Design Registration
- Canadian Registration Number (CRN)
- Pressure Piping Number (PP)
- Registered Welding Procedures, Welder Qualifications (AB 61, 68, 69, 70, 76a/b),
  Welding Examiner (AB 92), Accident and Unsafe Condition Reporting Requirements in
  Alberta (AB 15)
B31.3 Responsibilities
- Owner, Designer, Manufacturer, Fabricator, Erector, Owner's Inspector
Determining B31.3 Requirements (Appendix M)
- Normal, Category D and M Fluid Services
- High-Pressure Fluid Service
Brief Introduction to B31.3 Design Requirements (New Construction)
- Design Minimum Temperature
- Quality Factors for Welds
- Pressure Design of Straight Pipe
- Branch Connections, Flanges and Blanks
B31.3 Materials and Specifications
- Listed, Unknown and Reclaimed Materials
- Requirements for Low-Temperature Toughness Tests for Metals
  - Minimum Temperatures Without Impact Testing for Carbon Steel Materials
  - Reduction in Minimum Design Metal Temperature without Impact Testing
  - Acceptance Criteria
B31.3 Fabrication by Welding
- Responsibilities
- Brief Introduction to ASME B&PV Section IX (WPS, PQR, WPQ)
- Weld and Joint Types
- Preheat and Post Weld Heat Treatment (PWHT) Requirements
B31.3 Inspection and Testing for New Construction
- Responsibilities of the Fabricator, Purchaser and Inspector
- Examination Requirements: Extent, Supplementary and Typical Weld Imperfections
- Examination Methods for Evaluating Weld Imperfections and Acceptance Criteria
- Spot Radiography and Hardness Tests
ABSA's Role as the Authorized Inspector
- Pressure Equipment Safety Regulation
  - Integrity Assessment Programs
  - Owner's Responsibilities for Integrity Assessment
  - Qualification of Persons Performing Integrity Assessment
  - Conducting and Integrity Assessment
API 570 Inspection for Specific Types of Corrosion and Cracking
- Types of Inspection and Surveillance
- Thickness Measurement Locations and Methods
- Material Verification and Traceability
- Inspection of Welds In-service and Flanged Joints
API 570 Frequency and Extent of Inspection
- Piping Service Classes
- Inspection Intervals
- The extent of Visual External and CUI Inspections
API 570 Inspection Data Evaluation, Analysis, and Recording
- Corrosion Rate Determination
- Maximum Allowable Working Pressure Determination
- Retirement Thickness Determination
- Assessment of Inspection Findings
- Reporting and Records for Piping System Inspection
API 570 Repairs, Alterations, and Rerating of Piping Systems
- Repairs and Alterations
- Welding and Hot Tapping
- Rerating
API 570 Inspection of Buried Piping
- Types and Methods of Inspection
- Frequency and Extent of Inspection
- Repairs to Buried Systems
- Records