API 584/585: Pressure Equipment Integrity Operating Windows and Integrity Incident Investigation

About the Course

The API 584/585: Pressure Equipment Integrity Operating Windows and Integrity Incident Investigation training course is designed to provide participants with in-depth knowledge and practical skills necessary for effectively managing pressure equipment integrity and investigating incidents within industrial settings. It is essential for professionals working in industries where pressure equipment is a critical component of operational processes, including oil and gas, power generation, and chemical industries, which, based on the American Petroleum Institute (API) standards, offer a comprehensive understanding of the API 584 and API 585, and preparing participants for the challenges of maintaining equipment integrity while ensuring compliance with regulatory standards.

It is essential to establish Integrity Operating Windows (IOWs) for pressure equipment, a critical factor in ensuring the safe and efficient operation of systems where delegates will gain an understanding of the risk-based approach to setting IOWs, as well as how to monitor, manage, and respond to deviations from these established parameters. Furthermore, it covers best practices in documenting and maintaining IOWs, which are crucial for ensuring long-term asset integrity and performance. Through real-world examples, delegates will also explore integrating IOWs with other industry standards, ensuring alignment with established regulations and guidelines.

The latter portion of the training program focuses on integrity incident investigation, providing delegates with the tools and methodologies necessary for identifying the root causes of failures and understanding the degradation mechanisms that contribute to equipment malfunctions that will equip delegates with the skills to conduct effective investigations, preserve evidence, and formulate corrective and preventive action plans. Upon completion, they will be well-versed in maintaining equipment integrity, implementing industry best practices, and ensuring regulatory compliance, positioning them as key contributors to their organisations’ safety and operational efficiency.

Core Objectives

The delegates will achieve the following objectives:

• Know the scope, requirements, and key concepts of API 584 and API 585 relevant to pressure equipment integrity and incident investigation
• Explain the principles of Integrity Operating Windows (IOWs), including their types, limits, categories, and how they contribute to pressure equipment management
• Apply a risk-based approach to establish and manage Integrity Operating Windows for different pressure equipment systems
• Identify and analyse deviations and risks from established IOWs and assess the impact of process variables on equipment integrity
• Evaluate the effectiveness of Integrity Operating Windows monitoring and management systems, including IOW exceedance procedures and response actions
• Develop effective corrective and preventive action plans based on root cause analysis of integrity incidents
• Integrate incident investigation findings into comprehensive reports and communicate them effectively to relevant stakeholders

Training Approach

This training course utilises a combination of theoretical instruction, practical case studies, and interactive discussions to ensure a deep understanding of pressure equipment integrity and incident investigation. Delegates will engage in hands-on activities and real-world scenarios to apply key concepts in a controlled learning environment with collaborative learning, allowing delegates to exchange insights and best practices to enhance their industry knowledge and skills.

The Attendees

This training course is designed for pressure equipment maintenance, safety, and integrity professionals across various industries.

However, it will be particularly beneficial for professionals, including but not limited to the following:

• Integrity Engineers
• Materials & Corrosion Engineer
• Maintenance Engineers
• Reliability Engineers
• Process Safety Engineers
• Asset Managers
• Inspection and Testing Engineers
• Plant Managers

Daily Discussion

DAY ONE: ESTABLISHING INTEGRITY OPERATING WINDOWS (IOWS) FOR PRESSURE EQUIPMENT

• API 584 Scope and Requirements
• Defining Integrity Operating Windows – What are the Types, Limits, and Categories?
• Risk-Based Approach to Setting IOWs
• Process Variables Affecting Equipment Integrity: Monitoring and Management
• Degradation Mechanisms and Damage Mechanisms
• IOW Documentation and Change Management

 DAY TWO: IMPLEMENTING AND MANAGING INTEGRITY OPERATING WINDOWS

• API 584 Integration with API 570, API 579, and API 510
• Establishing Effective Monitoring and Data Collection Strategies
• Data Trending and Analysis: Identifying Deviations and Risks
• IOW Exceedance Management: Procedures and Response Actions
• IOW Audit and Compliance Verification
• Continuous Performance Evaluation: Feedback and Refinement of IOWs 

DAY THREE: INTEGRITY INCIDENT INVESTIGATION PROCESS

• API 585 Scope and Requirements for Incident Investigation Guidelines
• Investigation Triggers and Categorisation: Defining the Scope of Analysis
• Root Cause Analysis for Integrity Incidents Methodologies and Best Practices
• Data Collection and Preservation
• Failure Modes and Mechanisms: Recognising Degradation and Contributing Factors
• Reporting and Communication of Findings 

DAY FOUR: CONDUCTING EFFECTIVE INTEGRITY INCIDENT INVESTIGATIONS

• Incident Scene Management for Evidence Preservation
• Failure Analysis Techniques: Metallurgical, Mechanical, and Chemical Evaluations
• Human and Organisational Factors in Equipment Failures
• Integrity Management System (IMS) Integration for Incident Prevention
• Developing Effective Corrective and Preventive Mitigation Plans
• Structured Investigation Documentation and Reporting

DAY FIVE: COMPLIANCE, FITNESS-FOR-SERVICE (FFS), AND LONG-TERM MANAGEMENT

• Equipment Fitness-for-Service (FFS) Assessments and API 579 Integration
• Implementing Asset Integrity Programs
• Corrosion and Materials Considerations in Incident Investigations
• Integrity Management Performance Metrics and Benchmarking
• API 584/585 Audit Readiness: Key Considerations for Compliance
• Coordinating with Regulatory and Industry Bodies for Best Practices
• Examination Questions Overview
• Mock Examination