Petrotech Academy, Mahabubnagar
Major & Minor Overhauling of Static Equipment
In Oil & Gas / Petrochemical Plants
Storage tanks, heat exchangers, columns, furnaces, heaters, distillation and fractionation columns, vaporizers and other static equipment: plan, prepare, execute, inspect, test, document and close out overhauls to international codes and Saudi Aramco, SABIC, ADNOC and PDO standards.
20Modules
40 – 60Hours of training
Online / Classroom / BlendedMode
Upon Successful CompletionCertificate
Course overview
About this course
This course provides complete knowledge and practical skills required to plan, prepare, execute, inspect, test, document and close out major and minor overhauling of all critical static equipment in Oil & Gas and Petrochemical Plants, in accordance with international codes, Saudi Aramco, SABIC, ADNOC and PDO standards and best practices.
Who should attend
- QA/QC Engineers & Inspectors
- Mechanical / Inspection Engineers
- Maintenance Engineers
- Planning / Project Engineers & Turnaround Planners
- Supervisors & Coordinators
- Turnaround / Shutdown Personnel
Key competencies you will gain
- Plan and manage shutdown and turnaround of static equipment
- Inspect and evaluate condition using advanced NDT
- Repair, refurbish and test static equipment as per codes
- Ensure compliance with SAES, SABIC, ADNOC and PDO standards
- Prepare inspection reports and turnover documentation
- Ensure safety, quality and environmental compliance
- Optimize cost, time and resources during turnaround
Major and minor overhaul, and the turnaround workflow
Know what each type of overhaul covers, then follow the same eight-step workflow from planning to handover.
| Type | Scope |
|---|---|
| Major overhaul |
|
| Minor overhaul |
|
- 1Planning & Preparation
- 2Shutdown & Isolation
- 3Opening & Cleaning
- 4Inspection & Evaluation
- 5Repair & Refurbishment
- 6Testing
- 7Reassembly & Closing
- 8Post Overhaul & Handover
Complete course content
Twenty modules covering the full overhaul cycle, then five equipment-specific modules that apply it to tanks, exchangers, columns, furnaces and vaporizers.
Foundations: Scope, Standards, Planning, Pre-Turnaround and Shutdown
Introduction
- Overview of Static Equipment
- Importance of Overhauling
- Types of Overhaul: Major and Minor
- Objectives & Benefits
- Typical Damage Mechanisms (Corrosion, Erosion, Creep, Fouling)
- Challenges & Risks
- Roles & Responsibilities
- Interface with Other Disciplines
Codes, Standards & Client Requirements
- ASME, API & NACE Overview
- Saudi Aramco Standards (SAES, SAEP, GI, SIP, NMR)
- SABIC Standards
- ADNOC Standards
- PDO Standards
- Permit to Work System
- HSE & Environmental Requirements
Planning & Preparation
- Turnaround Strategy
- Scope Definition & Work Packs
- Equipment Criticality Ranking
- Resource Planning
- Manpower & Skill Matrix
- Tools & Lifting Requirements
- Materials & Spare Parts Planning
- ITP, WPS, Procedures Review
- Method Statement
- Schedule Development
Pre-Turnaround Activities
- Pre-Inspection & Condition Review
- Remaining Life Assessment
- Data Collection & Drawings Review
- Defect History & Trend Review
- Corrosion Under Insulation (CUI)
- Isolation Plan & Line Blanking
- Utilities Disconnection Plan
- Risk Assessment (JSA / HAZID)
- Permit Review & Approval
Shutdown & Isolation
- Safe Shutdown Sequence
- Depressurization & Draining
- Purging & Cleaning
- Isolation & LOTO
- Line Breaking & Spading
- Blind Installation & Verification
- Equipment Isolation Verification
- Gas Test & Safety Checks
Execution: Opening, Inspection, Repair, Testing and Reassembly
Equipment Opening & Preparation
- Manway / Nozzle Opening
- Component Removal
- Internal Cleaning
- Sludge / Deposit Removal
- Ventilation & Gas Freeing
- Fire Watch Arrangement
Inspection & Evaluation
- Visual Inspection (VT)
- Thickness Measurement (UT)
- NDT Methods (PT, MT, RT, UT, ET, TOFD, Phased Array)
- Corrosion Mapping
- Weld Inspection
- Fitness for Service (API 579)
- Inspection Reports
Repair & Refurbishment
- Weld Repair & Build-up
- Crack Repair (Grinding / Welding)
- Pad / Lifting Lug Repair
- Nozzle / Flange Repair
- Shell / Plate Replacement
- Tube / Internals Replacement
- Coating / Lining Repair
- Surface Preparation
Hydrotesting & Leak Testing
- Hydrostatic Test Procedure
- Test Pressure Calculation
- Test Medium & Temperature
- Test Setup & Safety
- Leak Test (Air / Helium)
- Post Test Inspection
- Test Documentation
Reassembly & Closing
- Component Reinstallation
- Bolt Tightening (Torque Check)
- Gasket / Packing Installation
- Alignment Check
- Nozzle Direction Check
- Internal Reassembly
- Final Inspection Before Closing
Close-out and Management: Handover, Quality, Safety, Tools and Cost
Post Overhaul Activities
- Post Overhaul Inspection
- Painting / Coating
- Insulation & Cladding
- System Line-up
- Pre-Commissioning Checks
- Punch Clearance
- Handover to Operations
Quality Control & Documentation
- Inspection & Test Plan (ITP)
- Checklists & Hold Points
- NDT Reports & Acceptance Criteria
- Material Test Certificates (MTC)
- Welder Performance Qualification
- NCR & Corrective Actions
- Dossier / Turnover File
Safety & Environment
- HSE Plan for Turnaround
- Risk Assessment (JSA)
- Work at Height
- Confined Space Entry
- Hot Work Permit
- LOTO Compliance
- Waste Management
- Environmental Protection
Turnaround Tools & Techniques
- Hydrotest Pumps
- Torque Wrenches
- Bolt Tensioners
- Lifting Gear & Hoists
- Confined Space Equipment
- Gas Detectors
- Grinding / Welding Machines
Cost & Performance Management
- Cost Estimation & Control
- Productivity Monitoring
- Delay Analysis
- Resource Optimization
- Lessons Learned
- KPI & Reporting
Equipment-Specific Overhauling Modules
Storage Tank Overhauling
- Roof, Shell, Bottom Inspection
- Floating Roof Inspection
- Tank Cleaning Methods
- Coating / Lining Repair
- Hydrotest & Acceptance
- API 653 Compliance
Heat Exchanger Overhauling
- Types of Heat Exchangers
- TEMA Components
- Channel / Shell Inspection
- Tube Inspection (UT / ET)
- Tube Bundle Removal
- Tube Cleaning & Replacement
- Reassembly & Hydrotest
- TEMA Compliance
Columns (Distillation / Fractionation) Overhauling
- Tray / Packing Inspection
- Internals Removal & Cleaning
- Repacking / Tray Replacement
- Downcomer & Weir Check
- Nozzle & Support Inspection
- Reassembly & Leak Test
- Alignment & Functional Test
Furnaces & Heaters Overhauling
- Burner, Tubes, Coils Inspection
- Tube Thickness (UT)
- Refractory Inspection & Repair
- Burner Alignment & Tuning
- Soot Blowing System Check
- Combustion System Check
- Performance Test
Vaporizers & Other Static Equipment
- Vaporizers (Ambient, ORV, SCV)
- Drums, Knock-out Drums
- Filters, Strainers, Coolers
- Reactors, Pressure Vessels
- Spheres, Air Coolers
- Inspection, Repair & Testing
- API 510 / 570 Compliance
Equipment covered, damage mechanisms and repair techniques
Equipment covered
- Storage Tanks (API 650 / 653)
- Heat Exchangers (TEMA)
- Columns (Distillation / Fractionation)
- Furnaces, Heaters, Reboilers
- Vaporizers (Ambient, ORV, SCV)
- Pressure Vessels
- Drums, Knock-out Drums
- Air Coolers, Coolers
- Filters, Strainers, Reactors
- Other Static Equipment
Common damage mechanisms
- Corrosion: uniform, pitting, crevice, galvanic
- Erosion and erosion-corrosion
- Stress corrosion cracking (SCC)
- Creep damage
- Weld defects: cracking, porosity, lack of fusion
Repair methods
- Welding and build-up
- Sleeving
- Patching
- Cladding
- Metal stitching
- Plugging
Practical sessions and case studies
Practical and workshop sessions
- Reading Drawings, P&IDs, Data Sheets
- Equipment Walkdown & Inspection Practice
- NDT Demonstration & Interpretation
- Thickness Measurement Hands-on
- Case Studies of Real Shutdowns
- Problem Identification & Solution Workshops
Case studies and lessons learned
- Case Study 1 – Storage Tank Internal Corrosion & Repair
- Case Study 2 – Heat Exchanger Tube Failure Analysis
- Case Study 3 – Distillation Column Tray Damage
- Case Study 4 – Furnace Coil Failure & Repair
- Case Study 5 – Turnaround Delay Causes & Mitigation
- Lessons Learned & Best Practices
Applicable client standards
The same overhaul steps, applied under the requirements of each client.
Saudi Aramco
- SAES Standards
- SAEP Procedures
- GI – General Instructions, SIP and NMR
- NACE MR0175 / ISO 15156
- API / ASME Codes
SABIC
- SABIC Engineering Standards (SES)
- SABIC Standards: 200, 300, 400 and 600 Series
- SABIC HSE Standards
- API / ASME Codes
- NACE / ISO Standards
ADNOC
- ADNOC Engineering Standards (AES)
- ADNOC Standards & Specifications
- ADNOC HSE Standards
- API / ASME Codes
- NACE / ISO Standards
PDO
- PDO Technical Standards
- PDO HSE Procedures
- API / ASME Codes
- NACE / ISO Standards
- Client & project-specific requirements
International and Indian standards you will work with
Overhaul work draws on ASME and API in-service codes, repair standards such as ASME PCC-2, ISO management standards, and Indian standards and statutory rules. The course teaches how to find the right requirement and apply it.
International standards
ASME, API, TEMA, NBIC, NACE, AWS, ISO, EN- ASME Section VIII Div. 1 & 2Pressure vessel design, fabrication, repair and testing
- ASME Section IPower boilers
- ASME Sections II, V and IXMaterials, non-destructive examination, welding qualification
- ASME B31.3 / B31.1Process piping and power piping
- ASME PCC-1 / PCC-2Bolted flange joint assembly, repair of pressure equipment and piping
- API 510 / 570 / 653In-service inspection of pressure vessels, piping and storage tanks
- API 650 / 620Welded storage tanks
- API 571 / 579 / 580 / 581Damage mechanisms, fitness-for-service, risk-based inspection
- API 936 / API 660 / 661Refractory installation quality control, heat exchangers, air coolers
- TEMA / NBIC (NB-23)Shell and tube exchangers, repairs and alterations of pressure equipment
- NACE MR0175 / ISO 15156 / MR0103Materials for sour (H2S) service
- AWS welding standardsWelding practice and qualification references
- ISO 9001 / 14001 / 45001Quality, environmental and occupational health and safety management
- EN 10204 (3.1 / 3.2)Types of material inspection certificates
BIS: Indian Standards
Bureau of Indian Standards (IS codes)- IS 2825Code for unfired pressure vessels
- IS 2002 / IS 2041Steel plates for pressure vessels
- IS 4503Shell and tube type heat exchangers
- IS 803Vertical mild steel cylindrical welded oil storage tanks
- IS 2062Hot rolled structural steel
- IS 814 / IS 7280Welding electrodes and bare wire electrodes
- IS 817 / IS 7307Training and testing of welders, welding procedure approval tests
- IS 2595 / IS 4853Radiographic testing of welds
- IS 3658 / IS 3703 / IS 4260Penetrant, magnetic particle and ultrasonic testing of welds
- IS 1363 / IS 1367Hexagon head bolts and nuts, threaded steel fasteners
Indian statutory and industry
Regulations and safety bodies- Indian Boiler Regulations (IBR)Boilers, steam pressure parts and repairs
- SMPV(U) Rules 2016 / PESOStatic and mobile pressure vessels (unfired), statutory requirements
- Factories Act, 1948Statutory provisions for confined spaces, pressure plant and safe working
- OISD standardsOil Industry Safety Directorate guidelines, including work permit and shutdown safety
- BIS certification (ISI mark)Verification of certified products at material receiving
- Client and project specificationsAlways override and extend the general standards
The standard and edition that apply depend on the contract and client specification. Participants are trained to confirm the governing document before work starts.
What you receive and how it is taught
Course deliverables
- Comprehensive Training Materials (Soft Copy)
- Standards & Procedures (SAES, SABIC, ADNOC, PDO)
- Inspection Checklists & Formats
- ITP Samples & Work Pack Templates
- Case Studies & Real Examples
- Turnaround Execution Plan Example
- Certificate of Completion
Training methodology
- Expert lectures (instructor led training)
- Real plant case studies
- Photos & videos
- Checklists & templates, report examples
- Interactive Q&A
- Assessment & certification
Course content at a glance
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Be a competent QA/QC professional for every turnaround
Ensure safety, quality, reliability and compliance by executing major and minor overhauling of static equipment to world-class standards.
Duration: 40 – 60 hours (Online / Classroom / Blended). Certificate on successful completion.